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 Supervisor: Students: Đỗ Ngọc Hiền Lê Thị Diễm Châu Nguyễn Anh Thy 2053487 Nguyễn Thiên Kim 2053174 Phan Văn Bách 2052865 Phạm Công Nghị 2053268 Đào Quang Chính 2052896 Ho Chi Minh City, 2022 TABLE OF CONTENT 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 mediumsized household businesses The procedure they apply to filtration and purification of the water as well as the packaging is almost irrelevant However, the issue we want to discuss is that millions of people now drink bottled water on a regular basis, primarily in Vietnam, and so bottled water production in household businesses has increased substantially in the previous decade The owners of these businesses hope that they can gain more profit and produce more products at cheaper prices Based on the above wishes, our research team would like to further improve the capacity of the input and add more filtration equipment to produce more outcomes Additionally, people will have access to quality bottled water for drinking at a low cost while still ensuring safety and health policies Our team believes that this improvement will yield a perfect bottled water drinking experience with superiority and healthiness 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 medium enterprises when grasping this promising number, they want to develop more in the production of bottled drinking water with the hope that the output volume will grow in both quantity 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 buy bottled drinking water because they not have enough time to boil the water for life as well 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 manufacture bottled water for these enterprises Simultaneously, our strategy can help these firms make a lot of money while providing safe and healthy water to their customers We would like to improve the capacity of the input, then propose a quality improvement and improve the packaging 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 main concern in logistics and work design fields The data is collected by using a stopwatch and written down Then it is broken down and processed with the use of charts Using a systematic 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 using charts Secondly, we need to examine the collected figures to find the issues in the operation and to come up with a solution (simplify, eliminate, combine or change some steps) for our problem After that, we develop a record of an improved method under prevailing conditions, reexamine and select the best method Then we have to evaluate several alternatives to developing a new improved method comparing the cost to effectiveness The next 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 improved method is in use III MATERIALS 3.1 Purification’s workstation 3.1.1 Previous operation With the labor forces are only in this workstation for all the steps conducted purified water treatment, the efficiency is not ensured, because not only the nature of the system but also the poor-condition machines and facilities themselves.Furthermore, the water origin is from 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 pumps with a capacity of 30HP which is 22500W and water flow of 144L/h In the coarse filter, treatment will pump up 14 blocks of water and use tanks for filtration, each filter tank is 250L/h In the RO,UV filter, there are UV lamps, Reverse Osmosis bars, purification 150L/h Ultraviolet light will be turned on during the whole running of the machine Filter up to time RO, Ultraviolet will cost 250L, filter time 250 liters cost 3-4 minutes ( all the machines and operators are also so obsolete that the process can not be at their best condition) Therefore, the finished product productivity in 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 product but also have good-quality water 3.1.2 Modification We have come up with improvements that are acceptable and suitable for the owner to make appropriate changes Whole operation requires machines, components with functions and ability: pumps, tanks and Reverse Osmosis, Ultraviolet purifying tanks: For the pumps, we come up with a recommended model: Product code 3M 40-160/4.0 Production brand Ebara pumps Electricity (V) 380V Wattage 5HP/4KW Flow (L/min) 200-700 Suction - discharge diameter (mm) 76-49 Origin EBARA ITALIA Continuously, for the tanks we use: Product code I 1000 Production brand Đại Thành Capacity (l) 1000l (H-L) ( mm) 1630-940 Suction - discharge diameter (mm) 76-49 Origin Việt Nam Finally, for the Reverse Osmosis, Ultraviolet purifying tanks we use: Name KENSI Parameter Number Pumps 1,5kW High pressure pump 2,5kW Composite 400x1625mm RO veil RO LE 4040 Sand purification valve F67 Fully automatic flushing valve F63 Pipes set Electricity system set Wattage 3.000 l / h Consumption voltage 3.2 KW / h Installation area 3.2 m2 Maximum wattage 1.700 l / h Restore 50 -75% Sodium rejection% 99,2% The water origin is from a nearby well which has a depth of 80m beneath the surface,… For the first process, they use pumps with capacity of 30HP which is 22500W and water flow of In the coarse filter, treatment will pump up 14 blocks of water and use tanks The water source is taken directly from the apartment's underground tank to flow through the iron treatment filter column by the pump The iron treatment column is capable of oxidizing dissolved metals in groundwater: Fe, As, Mn, thanks to the oxidation mechanism of KMnO4 on the surface of manganese sand Then, the water will flow through the coarse filter 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 hard water At this time, the plastic particles carrying the Na+ cation will exchange with the Ca2+, Mg2+ cations present in the water The cations Ca2+ ,Mg2+ will be retained on the surface of the exchange resin, the treated water will lose all the cations that cause hard water to create softer water to protect health, as well as daily activities RO water filtration system completely removes pollutants in the water, the water will flow through the fine filter cup With this filter cup, there are µm filters, so it will remove suspended solids, exchange resin particles left from the previous filter columns, creating a source of clean water for daily life The coarse filtration process in the 1500 L/h RO water purification system, the water is pushed through the high-pressure pump, this pump is responsible for pushing the water to a certain pressure to pass the RO membrane, because this RO membrane has a pore size The membrane is very small (0.0001µm), so it needs a strong enough pressure to push the water molecules through the membrane hole and at the same time it will retain the dirt on the membrane surface Create a source of clean, pure, and quality water After going through the filtration system, water will be stored in an accumulator, this accumulator will store purified water after the RO membrane and create pressure to push the water to the taps for indoor use With a period of time, raw water treatment processes, periodically the valves will automatically flush the material This process will take place regularly to increase the efficiency, as well as the life of the filter material Over a long period of time, new filter materials will be replaced to keep the system 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 processed per day Therefore, this adjustment has a better productivity but also guaranteed product quantity 3.2 Bottling workstation 3.2.1 Previous operation With the labor forces being in this workstation, the stages of water extraction, labeling and sealing are all done manually with the assistance of washing bottle machines, leading to low packing efficiency (10 minutes for a finished product) Not only that, the quality and shape 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 be safe or not First, they collected bottles and labeled their business name on it Then they clean the outside and wash inside and outside the bottle with distilled water After that, the bottles are transferred to a place where they extract water Finally, tighten the cap and seal the bottle to have a final product For the caps, we collected, cleaned and transferred to the exact station to use it As a result, in the observed workstation with a cycle time of day (8 hours 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 meet more 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: 10 Product code BT17 Production brand INTECH GR Wattage 2kw Length 5m Origin Việt Nam We came up with the idea of adding a conveyor belt to the process Because conveyor belts are 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 large dimensions Moreover, during the operation of the system, the machine runs very smoothly and 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 11 Moreover, by installing an UV projector beside water pipes while extracting water from tanks to bottle levels up the hygiene for the bottling process At wavelengths from 260-270 nm, UV-C rays will break the bonds in the DNA molecules of microorganisms, and create thymine dimers that can kill or inactivate microorganisms UV light helps to kill harmful germs and microorganisms such as E.coli, Staphylococcus, Influenza, Pneumophila… The installation of a UV lamp helps increase the effectiveness of disinfection instead of just cleaning the surface of the object with cleaning solutions Pipe material 304/316 steel Lamp power 55 W Input voltage 110V / 240V / 50Hz / 60Hz Number of UV bulbs 01 Pcs Filtration capacity 12 GPM (2.7 m3/h) Water capacity 2,810 cm3 Maximum operating pressure: 10 bar / (145 psi) 12 Test pressure : 15 bar / (218 psi) UV lamp failure alarm None Lamp life 8000 hours Dimensions Length : 950 mm, Height : 85 mm Steel pipe diameter 63.5 mm 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 method with very limited capacity The amount of labor involved in the large packaging operation has invisibly pushed up production costs This has affected the selling price as well as the competitiveness of the business with other units in the market So a water extractor is required For this, we have a recommended model: Capacity: 150-300 bottles/h (Designed according to customer requirements) 13 PLC control cabinet Water level sensor-Korea 03 automatic filling nozzles Automatic Conveyor For the bottle washing machine, we also have this model: Model BS-1 Compressed air pressure P 0.6 Mpa Power supply 220v/380v - 50Hz 14 Built-in washing brush pcs Suitable for Gallons (270 x 490 x 56 mm) flasks The bottling process is also necessarily needed, in order to cut off some stages to save some time, 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 the bottles, caps and clean it with distilled water After that, we put the cap on the bottle and transfer it to the conveyor Next, extract the water into the bottles, tighten it with the caps and then seal the final product 15 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 for the 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 a result, the time to extract water through the bottle and process the steps will be significantly shortened, thereby shortening the production time for a finished water bottle (2 and a half minutes), increasing productivity thereby optimizing time for the facility Therefore, the work efficiency is greatly improved and the process can produce about 200 to 250 bottles per day 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 of bottled water filtration and packaging process Our solution reduces the minimum time to complete product from 67 seconds to 37 seconds and reduces workers in the production 16 line Improvement will be conducted by implementing two main methods: motion improvement and comparing data charts 4.1 Motion improve: These tables show a clear change in cycle time to produce product Also the table shows the structure change of the production line, from people and machines to people and machines 17 18 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 19 4.2.2 Motion-chart of Optimized process 4.2.3 Compare data table Cycl Number e of Time Worker (s) s (person ) Unoptimize d process Optimized process 67 37 Time Wor k (%) Idle (%) 81.5 18.5 82.7 17.3 Number of Machin e Time Wor k (%) Idl e (% ) 60 40 Produc t Productivit y rate 4.5pc/min 8.1 pc/min 57 43 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 Reach for the cap TE TE Reach for the bottle Hold the cap and the bottle H U Clean the cap and bottle 20 Wash inside and outside of the bottle with distilled water Extract water Put the cap and bottle to conveyor TL TL Put the cap and bottle to conveyor Idle UD UD Idle Reach for the bottle and cap TE TE Reach for the bottle and cap Hold the cap H TL Put the bottle on washer Clean the cap U U Reach for the button to start the machine Hold the cap H H Hold the bottle Idle UD UD Idle 10 Lift up the cap H U Press the button to start extracting 11 Hold the cap H AD Idle 34 12 Place the cap on the bottle TL U Press the button to start tightening the cap 21 Seal the bottle 13 Idle UD UD Idle 14 Idle UD UD Idle 15 Reach for the sealer TE A Put the plastic seal on the bottle 16 Idle AD U Seal the bottle 17 Take the paper seal TL AD Idle 18 Idle AD A Put the paper seal on the bottle 66 4.2.4 Date comparation of the water’s quality after running through purification Water quality parameters Colour Turbidity pH TDS N-NH3 N-NH2 Clorua SO4 Iron level As (MLD = 0.001) Coliform E coli The production area that the team observed before improved 5.89 7.23 255 0.7 0.05 21 0.07 < 0.01 After apply improvements to the movement 7.04 254 0.05 < 0.03 21 0.021 < 0.01 Standard s of the Ministry of Health 15 6.0 – 8.5 1000 0.05 250 259 0.3 0.01 TCU NTU mg/l mg/l mg/l mg/l mg/l mg/l mg/l 1.1 0.08 0