AN ANALYTICAL STUDY OF PROCESS PARAMETERS OF PACKAGING FILMS: A CASE OF U-FLEX LTD., NOIDA

Abstract

Production and Process Industries’ operations are quite cumbersome. Manufacturing processes tend to produce operational wastages due to various reasons, which can be reduced by identifying and eliminating those reasons. To meet out the customers’ expectations and compliances of business world, vigilance during the production process is inevitable. Quality of Packaging Films produced through complex processes is affected by multiple variables. Traditional Statistical Process Control (SPC) methodologies are non-optimal to monitor and control these multiple variables as the effect of one variable can be confounded with the effects of other correlated variables. Further, the Univariate control charts are difficult to examine and analyze because of the large numbers of control charts of each process variable. An alternative approach is to construct a single multivariate T² control chart that minimizes the occurrence of false process alarms. This paper studies the application of Multivariate Statistical Process Control (MSPC) charts to monitor packaging film production process in a printing & packaging industry. T² diagnosis with Principal Component Analysis (PCA) is applied to analyze the critical process variables. Pareto Analysis is performed to identify the critical process variables for minimizing the rejections. Rewinder Tension and Line Tension are found to be the two most critical variables of the production process of packaging films