IMPROVING THE PROCESS OF PRODUCING BOTTLED DRINKING WATER IN HOUSEHOLD BUSINESS (2)

HO CHI MINH UNIVERSITY OF TECHNOLOGY OFFICE FOR INTERNATIONAL STUDY PROGRAM FACULTY OF MECHANICAL ENGINEERING DPARTMENT OF INDUSTRIAL SYSTEM ENGINEERING PROJECT REPORT IMPROVING THE PROCESS OF PRODUCING BOTTLED DRINKING WATER IN HOUSEHOLD BUSINESS A CASE STUDY

HO CHI MINH UNIVERSITY OF TECHNOLOGY OFFICE FOR INTERNATIONAL STUDY PROGRAM FACULTY OF MECHANICAL ENGINEERING DEPARTMENT OF INDUSTRIAL SYSTEM ENGINEERING

PROJECT REPORT

IMPROVING THE PROCESS OF PRODUCING BOTTLED DRINKING WATER

IN HOUSEHOLD BUSINESS: A CASE STUDY

Students:

II METHODOLOGY 4

III MATERIALS 5

3.1 Purification’s workstation 5

3.1.1 Previous operation 5

3.1.2 Modification 6

3.2 Bottling workstation 11

3.2.1 Previous operation 11

3.2.2 Modification 11

IV RESULTS AND EVALUATION 17

4.1 Motion improve: 17

4.2 Compare data chart: 19

4.2.1 Motion-chart of unoptimized process 19

4.2.2 Motion-chart of Optimized process 20

4.2.3 Compare data table 20

V CONCLUSION 22

REFERENCE 24

IMPROVING THE PROCESS OF PRODUCING BOTTLED DRINKING WATER

IN HOUSEHOLD BUSINESS: A CASE STUDY

ABSTRACT

Our study mentions the process of the manufacturing of bottled water in small and sized household businesses The procedure they apply to filtration and purification of thewater as well as the packaging is almost irrelevant However, the issue we want to discuss isthat millions of people now drink bottled water on a regular basis, primarily in Vietnam, and

medium-so bottled water production in household businesses has increased substantially in theprevious decade The owners of these businesses hope that they can gain more profit andproduce more products at cheaper prices Based on the above wishes, our research teamwould like to further improve the capacity of the input and add more filtration equipment toproduce more outcomes Additionally, people will have access to quality bottled water fordrinking at a low cost while still ensuring safety and health policies Our team believes thatthis improvement will yield a perfect bottled water drinking experience with superiority andhealthiness

Keywords: Producing bottled drinking water, Bottled water, Household business, Filtration

of bottled water, Purification of water

I INTRODUCTION

According to Nielsen's Fmcg report, the bottled pure water market in Vietnam saw a spike

of between 3.3% and 9.6% between mid-2015 and 2017 Moreover, small and mediumenterprises when grasping this promising number, they want to develop more in theproduction of bottled drinking water with the hope that the output volume will grow in bothquantity and quality to provide consumers with a safe and affordable product In addition,the real estate in Vietnam indicates that almost all workers who are not well-off wish to buybottled drinking water because they do not have enough time to boil the water for life aswell as not have the purification machine, so the demand in this field has increased strongly,and the consumers mostly want to purchase this product at the cheapest price and also clean

In this paper, we will delve deeper into the capacity to filter the water to manufacturebottled water for these enterprises Simultaneously, our strategy can help these firms make alot of money while providing safe and healthy water to their customers We would like toimprove the capacity of the input, then propose a quality improvement and improve thepackaging process by cutting off some of the unnecessary processes to shorten time

II METHODOLOGY

The optimization for a production line problem is a classic problem and a topic of mainconcern in logistics and work design fields The data is collected by using a stopwatch andwritten down Then it is broken down and processed with the use of charts Using asystematic method to study the issue, we can have a better view into it

The first task is to gather all the facts and numbers on the operation and display it by usingcharts Secondly, we need to examine the collected figures to find the issues in the operationand to come up with a solution (simplify, eliminate, combine or change some steps) for ourproblem After that, we develop a record of an improved method under prevailingconditions, reexamine and select the best method Then we have to evaluate severalalternatives to developing a new improved method comparing the cost to effectiveness Thenext step is to prepare for the installation, is to define the method, procedure, layout,equipment, working condition, materials and quality instruction The final step is to install

the improved method and maintain it by checking the operation regularly that the improvedmethod is in use.

a nearby well which can have bacteria, unknown diseases,… And their process of filtration

is not enough to filter out bad components in water

For the first process, they use 2 pumps with a capacity of 30HP which is 22500W and waterflow of 144L/h

In the coarse filter, 1 treatment will pump up 14 blocks of water and use 6 tanks forfiltration, each filter tank is 250L/h

In the RO,UV filter, there are 2 UV lamps, 2 Reverse Osmosis bars, 6 purification 150L/hUltraviolet light will be turned on during the whole running of the machine Filter up to 1time RO, Ultraviolet will cost 250L, filter time 250 liters cost 3-4 minutes ( all themachines and operators are also so obsolete that the process can not be at their bestcondition) Therefore, the finished product productivity in 1 day only reaches 7000l to 9000l

of water, resulting in the number of bottles of water being bottled and shipped sometimes

Therefore to improve the process, we need to modify and adjust to produce more productbut also have good-quality water

Suction - discharge diameter (mm) 76-49

Continuously, for the 6 tanks we use:

Suction - discharge diameter (mm) 76-49

Fully automatic flushing

valve

of KMnO4 on the surface of manganese sand Then, the water will flow through the coarsefilter column containing activated carbon This filter column will filter to remove odors,colors, and clean organic compounds in water

Hence, water is sucked up the water lines, flowing through the filter column to treat hardwater At this time, the plastic particles carrying the Na+ cation will exchange with theCa2+, Mg2+ cations present in the water The cations Ca2+ ,Mg2+ will be retained onthe surface of the exchange resin, the treated water will lose all the cations that cause hardwater to create softer water to protect health, as well as daily activities RO water filtrationsystem completely removes pollutants in the water, the water will flow through the finefilter cup With this filter cup, there are 5 µm filters, so it will remove suspended solids,exchange resin particles left from the previous filter columns, creating a source of cleanwater for daily life

The coarse filtration process in the 1500 L/h RO water purification system, the water ispushed through the high-pressure pump, this pump is responsible for pushing the water to acertain pressure to pass the RO membrane, because this RO membrane has a pore size Themembrane is very small (0.0001µm), so it needs a strong enough pressure to push the watermolecules through the membrane hole and at the same time it will retain the dirt on themembrane surface Create a source of clean, pure, and quality water After going throughthe filtration system, water will be stored in an accumulator, this accumulator will storepurified water after the RO membrane and create pressure to push the water to the taps forindoor use With a period of time, raw water treatment processes, periodically the valveswill automatically flush the material

This process will take place regularly to increase the efficiency, as well as the life of thefilter material Over a long period of time, new filter materials will be replaced to keep thesystem stable Fig.1 below briefly describes the process

Fig.1 Purification process with Reverse Osmosis and Ultraviolet system

With this new setting operations and modifications, 14000 liters of water can be processedper day Therefore, this adjustment has a better productivity but also guaranteed productquantity

3.2 Bottling workstation

3.2.1 Previous operation

With the labor forces being 6 in this workstation, the stages of water extraction, labeling andsealing are all done manually with the assistance of 2 washing bottle machines, leading tolow packing efficiency (10 minutes for a finished product) Not only that, the quality andshape of the bottled water can be damaged and affect the quality of the product inside

Moreover, hygiene is also a concern because the extraction process is not guaranteed to besafe or not First, they collected bottles and labeled their business name on it Then theyclean the outside and wash inside and outside the bottle with distilled water After that, thebottles are transferred to a place where they extract water Finally, tighten the cap and sealthe bottle to have a final product For the caps, we collected, cleaned and transferred to theexact station to use it As a result, in the observed workstation with a cycle time of 1 day (8hours of work), there are only 42 - 45 finished products

Because of that, we have to change the process of bottling to be more efficient and meetmore buyer’s demand

3.2.2 Modification

We need to make some improvements to improve the process of bottling

Firstly, the conveyor belt We have a new model for this:

Product code BT17

We came up with the idea of adding a conveyor belt to the process Because conveyor beltsare very suitable to be able to transport a large volume of goods ( in our case, water bottles,which have a volume up to 20 liters of water) have a wide conveyor surface and largedimensions Moreover, during the operation of the system, the machine runs very smoothlyand is easy to control The working capacity is quite high, can meet the needs of customers,simple design, easy to manage and operate This contributes to effective cost savings as well

as increased labor and production productivity in facilities

Moreover, by installing an UV projector beside water pipes while extracting water from

nm, UV-C rays will break the bonds in the DNA molecules of microorganisms, and createthymine dimers that can kill or inactivate microorganisms UV light helps to kill harmfulgerms and microorganisms such as E.coli, Staphylococcus, Influenza, Pneumophila… Theinstallation of a UV lamp helps increase the effectiveness of disinfection instead of justcleaning the surface of the object with cleaning solutions.

Maximum operating pressure: 10 bar / (145 psi)

UV lamp failure alarm None

Water inlet and outlet connector size : External thread : 0.75 inch (01 inch = 25.4

mm)

The process of packing water into bottles was usually carried out mainly by manual methodwith very limited capacity The amount of labor involved in the large packaging operationhas invisibly pushed up production costs This has affected the selling price as well as thecompetitiveness of the business with other units in the market So a water extractor isrequired

For this, we have a recommended model:

Capacity: 150-300 bottles/h (Designed according to customer requirements)

PLC control cabinet

Water level sensor-Korea

03 automatic filling nozzles

Suitable for 5 Gallons (270 x 490 x 56

The bottling process is also necessarily needed, in order to cut off some stages to save sometime, energy and money So, the process now has a number of steps (Fig.2)

First, collect bottles, label and clean the bottles and the caps In the next steps, we wash thebottles, caps and clean it with distilled water After that, we put the cap on the bottle andtransfer it to the conveyor Next, extract the water into the bottles, tighten it with the capsand then seal the final product

The process will be more productive to operate it and also ensure the quality of the goods

In the whole process the UV projector will be turned on in order to maintain the safety forthe environment around, ensure the least percentage of bacteria invasion to the products.With the help of a conveyor and water extractor, the process will have a faster flow of work,which will make whole operations more convenient and efficient than it used to be As aresult, the time to extract water through the bottle and process the steps will be significantlyshortened, thereby shortening the production time for a finished water bottle (2 and a halfminutes), increasing productivity thereby optimizing time for the facility Therefore, thework efficiency is greatly improved and the process can produce about 200 to 250 bottles

per

Fig.2 the bottling process with distilled water assistant for cleaning.

IV RESULTS AND EVALUATION

This section will discuss the method used to solve the waste of man-power and time ofbottled water filtration and packaging process Our solution reduces the minimum time tocomplete 1 product from 67 seconds to 37 seconds and reduces 2 workers in the productionline Improvement will be conducted by implementing two main methods: motionimprovement and comparing data charts

4.1 Motion improve:

These 2 tables show a clear change in cycle time to produce 1 product Also the table showsthe structure change of the production line, from 6 people and 4 machines to 4 people and 5machines

Table 3.1 Unoptimized operator machine chart

Table 3.2 Optimized operator machine chart

4.2 Compare data chart:

4.2.1 Motion-chart of unoptimized process

4.2.2 Motion-chart of Optimized process

4.2.3 Compare data table

CycleTime(s)

NumberofWorkers(person)

ofMachine

t

Productivit

y rateWor

k(%)

Idle(%)

Work(%)

Idle(%

)

Unoptimize

81.50

17.3

8.1 pc/min

4.3 Right-hand/left-hand activity chart of the improved process

Clean the cap Sequence Left hand Therbligs Right hand Cummulative

time (s)Left Right

cap andbottle

4

3 Put the

cap andbottle toconveyor

TL TL Put the cap

and bottle toconveyor

the bottleand cap

button tostarttightening

1

seal on thebottle

After apply improvements

to the movement

Standard

s of the Ministry

V CONCLUSION

Our research has been carefully considered to advance some improvements in increasing thecapacity for the input as well as in the purification process Hence, our team has helpedhousehold businesses get more profit and also save processing time; moreover, consumerscan have a large number of products to use

To conduct this research, our team has studied the old procedure in some real-life businesses

to find out what they need to improve the process to give benefits to both the owners andusers Firstly, we recommend some machines that can boost the capacity as well as theeffect for the whole process by finding some machines and equipment that have effectiveproductivity Second, we increased the number of tanks to six to allow for more water inputand to accommodate the purification systems Finally, we make some comparisons abovethe motion in the process of worker and machine between the old and current ones

For the purification, after adding the recommended model the quality of water is finer thanthe original process The product’s parameters are safer and more suitable to consume

We have analysed the job and also the motion of each worker and the productivity ofmachines in the old process Therefore, we decided to change the structure from 6 peopleand 4 machines to 4 people and 5 machines by optimizing the process Moreover, the cycletime of the process of bottling has decreased from 67 to 37, which is 1.81 times less than theoriginal one As a result, the productive rate has increased to 8.1 product per min