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Jagran Prakashan Limited
Case Study on
Newsprint Waste reductionSubmitted to D L Shah Quality Award Competition - 2015
Dainik Jagran - NoidaD : 210 – 211, Sector – 63, Noida (UP)
CONTENTS
CONTACT DETAILS 2
EXECUTIVE SUMMARY 3
BRIEF HISTORY 5
WORK FLOW 7
PROJECT CHARTER 8
PLAN (IDENTIFICATION OF PROBLEM & ROOT CAUSES) 9
DO & CHECK (IMPLEMENTATION and CHECK RESULTS) 15
FINANCIAL BENEFITS 29
INTANGIBLE GAINS 30
STANDARDIZATION 31
IMPROVEMENTS 32
TOOLS USED 35
Dainik Jagran PROJECT - NEWSPRINT WASTE REDUCTION Page 1 of 35
CONTACT DETAILS
Chief Executive:
Mr. Sandeep Gupta
Coordinator:
Mr. Satish Chandra Mishra, Mr. S K Singh & Mr. Neetendra Srivastava
Project Leader:
Mr. Beer Bahadur Singh
Mobile: 09560798140
Team members:
Mr. Anil Kandhol
Mr. Durga Prasad
Mr. Pramod Sharma
Company Address:
Jagran Prakashan Limited
D : 210 -211, Sector – 63,
Noida (UP)
Dainik Jagran PROJECT - NEWSPRINT WASTE REDUCTION Page 2 of 35
EXECUTIVE SUMMARY
Newsprint is the major cost contributor among all consumables in the Newspaper
printing process. We are using 85% indigenous newsprint.
Initially, after identification of the problem, a Continuous Improvement Group –
Newsprint (NP) was formed. The group works for improvement of processes in the
organization and the project scope covers waste reduction in all Newsprint categories –
Print, Reel-end, Tear- off and Sweep waste. The team used the PDCA cycle to identify
opportunities for improvement.
Data analysis was carried out with the help of different statistical tools. After Pareto
analysis, it was found that Print, Reel-end and Tear-off wastes are the major
contributors of Newsprint waste. To know different causes leading to Print waste, a
Cause and effect diagram was prepared. Similarly, 5 Why analysis helped determine
the root causes for Reel-end waste and Tear-off waste.
Ideas were generated to improve the process and reduce the newsprint waste in all
categories. Acceptable ideas were implemented by the CIG - Newsprint team with the
help of other departments and senior management.
Control charts were used to monitor the progress and the team tried to eliminate all
assignable causes. Finally the values were monitored with I-MR charts to see whether
the process lies between specified limits.
Dainik Jagran PROJECT - NEWSPRINT WASTE REDUCTION Page 3 of 35
After implementing all the acceptable ideas, the result (Newsprint waste %) was
compared with the base data (4.97%).
This case study would trace the journey in reduction of newsprint waste from 4.97 % to
4.28%.
The team achieved improvement of 13.88% compared to the target of 10% reduction.
Now efforts are made to monitor the process by using different tools to improve &
sustain it.
Dainik Jagran PROJECT - NEWSPRINT WASTE REDUCTION Page 4 of 35
Dainik Jagran
Brief information about the organization:
Dainik Jagran is professionally organized company and printed the newspapers in
many languages like Hindi, Punjabi, Urdu, English as well as Sakhi and Josh
magazine also published from here. As of now 32 branches we have in various states
of the India.
MID DAY and NAI DUNIA is also integral part of the Dainik Jagran.
Dainik Jagran PROJECT - NEWSPRINT WASTE REDUCTION Page 5 of 35
Noida Plant:
The Noida plant started operating from its present location of Sector – 63, Noida UP.
Now this year is going to celebrate the silver jubilee after successfully completing of 25
Years. Over the years, the operations increased manifold to make it one of the biggest
newspaper printing plants in India. At present, the editions being printed at the plant
include Jagran, Jagran National, Nai Dunia, Inqulab,
The Vision statement of Production Department is:
“Creating an entrepreneurial culture of innovation and
empowerment to achieve sustainable technology leadership
in print and beyond”
Dainik Jagran PROJECT - NEWSPRINT WASTE REDUCTION Page 6 of 35
WORKFLOW OF THE PRODUCTION DEPARTMENT
Dainik Jagran PROJECT - NEWSPRINT WASTE REDUCTION Page 7 of 35
Editorial department releases the pages via leased lines to the Plate making department
which prepares the plates for mounting on machine. In production department printing is done
on paper and delivered to the mail room department. Finally dispatch department distributes
newspaper to the customer.
PROJECT CHARTER
Project Name:Newsprint waste reduction at Dainik Jagran – Noida (UP)
Business CaseNewsprint is the largest cost component among variable cost. Newsprint waste % figures for FY 12 – 13 is 4.97% which needs to be improved.
Project ObjectivesTo reduce Newsprint waste by 10% from 4.97 % to 4.48 % by March 2014. Also reduced from 4.47% to 4.28% till Dec, 14.
Expected Savings 10% waste reduction translating to Rupees 38.89 Lac for 2013-14 and also rupees 15.55 Lac. till date Dec,14
Project ScopeNewsprint waste reduction savings shall include savings due to waste reduction in all categories of the Newsprint.
Project Schedule Team Members and other resources
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Project Identification 01/04/2012Champion Mr. Sandeep
Gupta
Plan 02/04/2012 Team Leader Mr. Beer Bahadur Singh
Do 15/04/2012Team Members:
Mr. Anil Kandhol
Mr. Durga Prasad
Mr. Pramod Sharma
Mr. M P Singh
Check 15/09/2013
Act01/12/2013
Close 31/03/2015
Signature Champion:
Mr. Sandeep GuptaOther Resources
MIS reports.
Production Report
IDENTIFICATION OF THE PROBLEM
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The Newsprint is the printing paper which is used to produce a newspaper. The paper
is supplied by the papermaking mills in the form of reels. These reels have different
specifications such as different sizes, color, GSM, pulp quality etc.
After manufacturing, the reels are loaded in containers and delivered through ships by
the papermaking mills. The containers are offloaded at destination seaports, brought to
warehouse via trains, stored, before being ultimately delivered to the printing sites with
the help of trucks and forklifts.
DVC: Other than the newsprint several materials such as ink, plates, chemicals,
electricity, water etc. are required in the production of a newspaper.
There are certain wastages occurring in the process of producing newspaper as shown
in the structure below.
Dainik Jagran PROJECT - NEWSPRINT WASTE REDUCTION Page 10 of 35
Newsprint Waste Generation
Press Operation Newsprint HandlingProject focus
Project focus
Newsprint waste generation chart
Jagran Noida plant consumed 15581 MT of newsprint in 2012-13 with newsprint waste
percentage of 4.97 %. Since newsprint is the major contributor to the consumable cost,
even slight reduction of newsprint waste would lead to huge savings and improve the
operational and financial efficiency of the printing plant. Therefore, efforts were done to
reduce the newsprint wastage through continuous process improvement.
Keeping in view the scope of above stated reduction, it was decided to form a
Continuous Improvement Group (CIG) for Newsprint waste reduction with an objective
to reduce newsprint waste by 15% from the baseline figure 4.97 % of FY 12 – 13 to
10% in next FY is 4.47 %.
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Printed waste
Reel –end waste
Tear off waste
Transit waste Forklift operation
Sweep waste
Tear-off
Waste during run
Start- up waste Auto splice waste
White waste
Register out
Late copy clearing
DEFINITIONS OF NEWSPRINT WASTE CATEGORIES
TEAR-OFF WASTE
SWEEP WASTE
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Tear -off due to transit damage
A newsprint reel brought to the shop
floor is loaded on the reel stand of
the press where the wrapper is
removed.
The top most layers (which are
damaged due to transit) are sliced
off. This is called “Tear- Off” waste.
The waste of top 2.5% of reel
diameter is equal to 9.85% of total
reel weight.
The paper is then threaded through
the press due to which some amount
of it is wasted. This is called “Sweep”
waste.
PRINTED WASTE
REEL- END WASTE
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The copies that get wasted to
get the saleable copy (i.e. gross
counter minus net counter)
amounts to “Printed” waste.
The butt end of the newsprint reel that
is left behind after splice is called “Reel-
end” waste.
BASE DATA
The base data was taken for the period April-08 to Mar-10 as shown in
the table below.
FY 2012 - 13
Months Consumption (Kg)Waste %
April,12 1465835 4.76May,12 1480760 5.04June,12 1427770 5.37July,12 1514297 5.56Aug,12 1357963 5.25Sep,12 1339418 4.74Oct,12 1478550 4.96Nov,12 1399658 4.86Dec,12 1359095 4.96Jan,13 1429518 4.93Feb,13 1328578 4.45March,13 1421252 4.70Average 1416891 4.97
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DIAGNOSTIC APPROACH FOR PROBLEM SOLVING
The CIG Newsprint team adopted PDCA methodology for the continual
improvement in the Newsprint waste reduction area.
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STEP 1 :- Plan for a change
STEP 4 :- Redefine the change as necessary
STEP 3 :- Observe the results
STEP 2 :- Try plan on a small scale
After collection of data, a pareto analysis was done to determine the vital few causes
leading to Newsprint waste.
86% of the waste is due to Print waste, Packing and Tear-off.
Print waste, Reel-ends and Tear-off are in the priority list to reduce Newsprint
waste.
After discussions within CIG- NP team, it was decided to use below mentioned tools for
analysis of root causes:
Causes Tools used
Print waste Cause & effect diagram
Reel-end waste 5 Why analysis
Tear-off waste 5 Why analysis
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CAUSE AND EFFECT DIAGRAM
Brainstorming was done to prepare a cause and effect diagram to determine various
causes leading to Print waste.
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Man
Component malfunction
Compressor trip
Auto splice failure
PRINT WASTE
Improper diagnosis
Catch-up due to fluff
Moisture
Materials
Wrinkles due to dryness
Scum due to roller ageing
Improper Blanket cleaning
Machine
Method Environment
Dirty web eyes
Human error
Scum due to roller washing
Wrong plate mounting
Awareness regarding newsprint handling
Unskilled operator
Splice copies
Mis-registration during running
Folder jam
Incorrect electrical parameters
Incorrect tension values
Spray problem
Test run
Reel inspection method
Warehouse conditions
Reel turning brittle
Image wear-off
Mis-registration after brand change
Web wandering
Loose winding
Out of round reels
Mill joint failure
Inside sticky reelPoor slitting
Core slippageInside cut
Run sequence
Scum
No scientific procedures for reel unloading
Loose sheet after splice
Sensor activated
Predetermined by manufacturer Component malfunction
After determining probable causes leading to Print waste, significant causes were
chosen with consensus as shown below.
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Man
Auto splice failure
PRINT WASTE
Improper diagnosis
Improper Blanket cleaning
Human errors
Wrong plate mounting
Awareness regarding newsprint handling
Unskilled operator
Scum
No scientific procedures for reel unloading
Wrong plate mountingInsignificant causeAwareness regarding newsprint handlingSignificant causeAuto splice failureInsignificant causeImproper diagnosisInsignificant causeImproper blanket cleaningInsignificant causeHuman errorsInsignificant causeUnskilled operatorInsignificant causeScumInsignificant cause
Dainik Jagran PROJECT - NEWSPRINT WASTE REDUCTION Page 19 of 35
Component malfunction
Compressor trip
PRINT WASTE
Machine
Splice copies
Mis-registration during running
Folder jam
Incorrect tension values Incorrect electrical parameters
Turbo problem
Loose sheet after splice
Sensor activated
Mis-registration during running Insignificant cause
Folder jam Insignificant cause
Component malfunction Insignificant cause
Compressor trip Insignificant cause
Incorrect tension values Insignificant cause
Incorrect electrical parameter Insignificant cause
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PRINT WASTE
Method
Dirty web eyes
Scum due to roller washing
Test run
Reel inspection method
Run sequence
Predetermined by manufacturer
Scum due to roller washing Insignificant cause
Reel inspection method Insignificant cause
Dirty web eyes Insignificant cause
Test run Significant cause
Run sequence Significant cause
No fixed counter for copy checking
Predetermined by manufacturer
Component malfunction
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PRINT WASTE
Moisture
Wrinkles due to dryness
Environment
Warehouse conditions
Reel turning brittle
Warehouse conditions Insignificant cause
Moisture Insignificant cause
Wrinkles due to dryness Insignificant cause
Reel turning brittle Insignificant cause
Component malfunction
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PRINT WASTE
Catch-up due to fluff
Materials
Scum due to roller ageing
Image wear-off
Mis-registration after brand change
Web wandering
Loose winding
Out of round reels
Mill joint failure
Inside sticky reelPoor slitting
Core slippageInside cut
Slitter grinding required
Catch-up due to fluff Insignificant cause
Image wear-off Insignificant cause
Scum due to roller ageing Significant cause
Mis-registration after brand change Insignificant cause
Web wandering Insignificant cause
Loose winding Insignificant cause
Out of round reels Insignificant cause
Mill joint failure Insignificant cause
Inside sticky reels Insignificant cause
Core slippage Insignificant cause
Inside cut Insignificant cause
Component malfunction
5 – Why Analysis to find out root-cause of Reel-end waste
ACTION PLAN
Optimize the reel-end cut diameter to the lowest possible value.
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High reel-end waste
Leftover generated by the
machine
To avoid splice failure
Reduce cut dia required
Why? Why?
Why?
Solution
Some length required by flying autosplicer
5 – Why Analysis to find out root-cause of Tear - Off waste
ACTION PLAN
Regular inspection of forklift rubber pads.
Dainik Jagran PROJECT - NEWSPRINT WASTE REDUCTION Page 24 of 35
High Tear-off waste
Due to transportation
damage
Poor condition of forklifts clamp
rubber pads and unskilled operators
Reduce handling damage by
Changing forklift clamp rubber pads
Dock leveler for unloading reels
Emami reels transportation by train
Why? Why?
Why?
Solution
Poor handling of reels during
loading/unloading at vehicles/ warehouse
Best Practices:
Idea & Best Practices Waste CategoryImparted training regarding newsprint handling and awareness
Tear – off & print waste
Regular inspection of forklift rubber pads. Tear - off
Run sequence modification Print wasteReduction of pasting failures Print waste
Reduction of web breaks Print waste
Reduction of Start up waste Print waste
Followed Preventive SOP Print waste
Acquire and note the press parameters like LR & CR.
Print waste
Proper followed the check points & settings
Print waste
Dainik Jagran PROJECT - NEWSPRINT WASTE REDUCTION Page 25 of 35
Awareness regarding Newsprint Handling:
a) Providing reel cushions during unloading to prevent Out Of Roundness
(OOR)The reels are now dropped on a cushion made of foam to minimize the
impact if left directly on the floor.
Before After
Dainik Jagran PROJECT - NEWSPRINT WASTE REDUCTION Page 26 of 35
b) Protecting left over reels to reduce Tear- Off waste
The leftover reels after printing are properly wrapped so as to avoid damage to
top layers by incision of foreign materials lying on the floor.
Inspection of Forklift pads to prevent side damage to the reels and
maintain clamp force to reduce out of roundness
Damaged forklift pad New forklift pad
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Worn out Forklift pads causes cuts and damages to the newsprint while gripping.
Regular inspection is done to check its condition and to be replaced if required.
Clamp force to be set to an optimum level (15 KN for 1000 kg reel) to avoid Out of
Roundness at the time of gripping the reels.
Reel- end diameter reduction and improvements:
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FINANCIAL BENEFITS & BUSINESS RESULTS
Saving Calculation details
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INTANGIBLE GAINS
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STANDARDIZATION
Standard Operating Procedures for different processes were made. Following are the
list of processes:
Reel Make-ready
Cushion for Reel Unloading
Ink & Water Curve check
Run sequence.
Reduction of web breaks & Pasting Failures.
Reduction of change over Time.
Control charts & Bar graphs:
Printed waste control charts are being used every month to monitor the variation.
Appropriate actions are taken for any variance reflected.
Following are the Bar graphs used to monitor the machine performance:
Newsprint waste
Newsprint yield
Web breaks
Startup waste
Average speed
Average downtime
Dainik Jagran PROJECT - NEWSPRINT WASTE REDUCTION Page 32 of 35
SUSTAINABILITY
Training & Developments:
Dainik Jagran PROJECT - NEWSPRINT WASTE REDUCTION Page 33 of 35
Improvements:
I-Chart of Newsprint Yield.
I-Chart of Newsprint Waste.
Dainik Jagran PROJECT - NEWSPRINT WASTE REDUCTION Page 34 of 35
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TOOLS USED FOR ANALYSIS
Dainik Jagran PROJECT - NEWSPRINT WASTE REDUCTION Page 36 of 35