Analysis and improvement of lubricant blending cycle-time inconsistency using QC tools

Lim, Jin Tzen (2016) Analysis and improvement of lubricant blending cycle-time inconsistency using QC tools. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

This main concern of this project is to identify and remove the causes of inconsistent processing time during blending process in AsPac Lubricants (Malaysia) Sdn. Bhd., the lube oil manufacturing industry located at Port Klang. The objectives of this project are to identify the root cause of inconsistent blending cycle time using various quality tools and to propose solutions in addressing the root cause of inconsistent blending cycle time. Check sheet has reviewed that out of specification blend as major problem. Meanwhile, the moving chart showed that the blending process is in a state of control and focus to solve systematic issues. For the purpose of brainstorming, an interview and questionnaire were carried out. After eliminating the hypothesis that majority do not agree and verified by 5-Whys analysis, the major problem that has been confirmed is the inefficiency of blender to provide 100% of circulation in one cycle. To address the problem, electrical impedance tomography method is suggested to monitor the blending process. Besides, three methods are proposed to redesign and improve the performance of blending machine which are adding a more viscous material to less viscous material, add minor ingredients to the less viscous material and reduce the batch size. Furthermore, PDCA is recommended to maintain the sustainability of the proposed solutions.

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