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Newsprint Waste Reduction by Application of Scientific Problem Solving (PDCA)
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(May 17, 2020)

Newsprint is the major cost contributor among all consumables in newspaper printing process accounting for more than 80% of the consumables cost. The average Newsprint waste percentage is 3.61 at TOI Sahibabad plant against a consumption of 182804 Metric tons. Any reduction in newsprint waste percentage will generate huge financial savings for the organization. Initially, after identification of the problem, a Continuous Improvement Group – Newsprint (CIG- NP) was formed to reduce all categories of Newsprint waste by using 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. 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. This case study would trace the journey in reduction of newsprint waste from 3.61 % to 3.19%.

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