Aradhana Softdrinks Maintenance Strategy

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Aradhana Soft Drinks Company, PANIPAT, INDIA

Support from Autonomous

Maintenance for Break DownReduction

Surender Kumar Sharma

General Manager (North Operations)Pepsico India


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PEPSICOPepsico World wide

FY09 revenues of $ 60 billion,

with an average annual growthrate of 12% over the past 15years

2ND Largest Food andBeverage company in theWorld

Over 180,000 professionals in

200 countries and

PepsiCo India

3RD Largest FMCG company in

India

42 Plants including snacks

30% Growth in FY 09


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Our Brands


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PLANT ESTABLISHED IN 1991ACQUIRED BY PI IN 2003

Plant area-10 Acres ( 39452 Sq. mt )

Lines Rated Capacity

CSD GRB 550 BPMCSD PET MS 80 BPM

CSD PET SS 300 BPM

CSD BIB 100 BPM @ 12 L

Slice GRB 200 BPM

Slice HY PET 73 BPM

TOTAL 1203

Site Information

Full Time Employees

Managers 6

Executives - 34

Associates - 116


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Manufacturing ProcessBlow Moulding M/cs Filler Warmer

Sleever

LabellerEmpty Light Inspection

Taping M/cs

MIX Processor


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Story of Transformation


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Journey at Aradhana soft Drinks Panipat


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TPM ORGANISATION

Lead Plant

Manager

Plant Manager

Departmental manager

Line FPRs(First person responsible)

Associates

Steering Committee

Departmental Committee

Circles

Jishu Hozen

Kobetsu Kaizen

PlannedMaintenance

Quality

Maintenance

Initial FlowControl

Office TPM

Education &Training

Safety Health &Environment

Pillar SubCommittee

Corporate Steering Committee

TPM Secretariat

Pg No.17


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Targets and Goals


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Master Plan


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Autonomous Maintenance


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Approach

Circle Name:- Golden LionCircle Member :- Kulvinder singh, Prakash Kumar, Sunil Singh, Pankaj Makkar, Rakesh Kumar,Rizwan, Tamjeed

Forming of Team

Identification Model

M/CS

Forming & Performingof CLITA & Tagging

List of Hard to CLITA &Sources of Contamination

Countermeasure for Hard to CLITA& Sources of Contamination

Making of Kaizens& OPLS

Forming of CLITA Standard& Results

General Inspection


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STEP ZERO ACTIVITIES

Each Circle Leader and Circle members were givenboth Class Room as well as on the job training

Special emphasis was given on Safety while doing JH Selected The Model Machine

IMPLEMENTING 1S/2S ACROSS PLANT All Unnecessary items were removed Place was designated for all items Examples of 3S activities carried out in the Plant

are given in the following figures.

JH TRAINING - CLASSROOM/ON - THE - JOB

Customization ofTool Board

Closed By Maintenance Closed By Operator

Red FuguaiTag

White Fuguai Tag


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Manager Model Machine

Model Machine

BEFORE AFTER

Forming of Team


M/CS






General Inspection


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Lubrication Map of

Popular Circle

CoolingTunnel

BufferConveyor Sleever

HeatingTunnel Collecting

Table

Step 1

Before After Before AfterBefore After

Forming of Team


M/CS






General Inspection


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Step1

Forming of Team


M/CS






General Inspection


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Step-2Process Flow Chart

BEFORE AFTER

Forming of Team


M/CS






General Inspection


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Forming of Team

Identification ModelM/CS






General Inspection


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Step-2Process Flow Chart Special Type of Puller Made for Vent Tube ChangingVent Tube Chuck nut Made of Teflon

Forming of Team


M/CS






General Inspection


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Forming of Team







General Inspection


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For ease of Inspection and early detectionFor checking abnormalities in critical process parameters.

Jishu -Hozen visual controls

VISUAL CONTROLS

Pg No.46


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Step-4PREPARATION

TRAINING

GENERAL

INSPECTION

AUDIT

0

1

2

3

4Fastner

Drive

Lubrication

Pneumatics

Hydraulics

Electrical

safety

Mc. Condition

BM Actual

Target

Training

OPL

Working

ModelCut-

sections

Manuals

General

Inspection

Sheets

OJT

Training Model

OEM Training

TRAINING AIDSForming of Team







General Inspection


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Aradhana Soft Drinks Company, PANIPAT, INDIABEFORE AFTER

THEME: Hot Water Tunnel after Filler Prepared to AvoidWastage of Water and Steam.


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THEME: Preheating Hot Water Tunnel Prepared to avoidWastage of Water and Steam.

BEFORE AFTER


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THEME: Prepared Auto Controller of Hot Water forPasturiser Water tank.

BEFORE AFTER


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THEME: Repositioning of the Level Sensor to minimize thebottles loss.


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THEME: Putting another valve closure to reduce thebeverage loss in 600mL.


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THEME: Putting another valve closure to reduce the beverageloss in 600mL.


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THEME: Cap Stopper installed to avoid inverted capentering into Capper Line 2 filler.

BEFORE AFTER


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THEME: Air knife removed by using the blower air forremoving the water particles from bottle.

BEFORE AFTER


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BEFORE

THEME:CARBO-COOLER MIXING PUMP EARTHING

DONE

AFTER


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BEFORE

THEME:PROPER PVC GLAND FITTED

AFTER


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BEFORE AFTER

THEME: Extra conveyor support SS clamped cut.


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BEFORE AFTER

THEME:FILLER TABLE TOP PROFILE GZC 107 NEW

CHANGED


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BEFORE

THEME:MOTER DIRECTION INDICATED

AFTER


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BEFORE

THEME:SU PIPE NYLON BLACK SUPPORT FITTED

AFTER


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BEFORE

THEME:GREASE NIPPLE FITTED OF CONVEYOR

GEARBOX

AFTER


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BEFORE

THEME: CARBOCOOLER S.C.FM ROTA METER

CHANGED

AFTER


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BEFORE

THEME:DRAIN LINE WELDING CRACKED

AFTER


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BEFORE

THEME:SU PIPE NYLON SUPPORT FITTED

AFTER


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BEFORE

THEME:IN CARBOCOOLER U.V LIGHT PRESS. GAUGE

FITTED IN REVERSE DIRECTION.

AFTER


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O.E.E= L.P.* Conc Yield


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Total Plant Productivity


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64

68

7987

92 92 90

0

20

40

60

80

100

%

2005 2006 2007 2008 2009 Till

Jun

2010

Year

Total Tag Compliance

B e nc hM a rk A c t ua l T a rge t

5.535.47

6.11

6.05

6.86

8.408

0

1

2

3

4

5

6

7

8

9

%

2005 2006 2007 2008 2009 Till

Jun2010

YearBenchMark Actual Target

Skill Level (Operator)


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2.00

2.21

2.61

3.2 3.232.88

3.60

0

1

2

3

4

Averag

eLevel(1

to

4)

2005 2006 2007 2008 2009 Till

Jun2010

YearBenchMark Actual Target

00

5

7

10 10

15

0

3

6

9

12

15

No/Year

2005 2006 2007 2008 2009 Till

Jun

2010Year

Internal Trainer

BenchMark Actual Target

1500

Total no. of Kaizens


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21

275

524

974

1234

1326

1500

0

300

600

900

1200

1500

N

o's

2005 2006 2007 2008 2009 Till

Jun

2010YearBenchMark Actual Target

0

258

444

957

13321429

1500

0

300

600

900

1200

1500

Cum.

No.

2005 2006 2007 2008 2009 Till

Jun

2010

Year

OPL's

B enchM a rk A ct ua l T arget

Quality - BrixQuality - GV


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98 98.2799.4010099.44 100 100

0

25

50

75

100

N

o's

2005 2006 2007 2008 2009 Till

Jun


100100

100 99.44 100100

0

25

50

75

100

Cum.No.

2005 2006 2007 2008 2009 Till

Jun

2010

Year

Quality TA

B e nc hM a rk A c tua l T arge t

89 91.3893.0694.8692.22 92.22 95

0

25

50

75

100

N

o's

2005 2006 2007 2008 2009 Till

Jun



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2006

2007

2008

2009

CHAIRMAN AWARD RECEIVED FOR REDUCTION IN WATER

CONSUMPTION

AWARDED WITH TPM GOLD KAIZEN AWARD INPEPSI INDIA KAIZEN CONFERENCE

ZERO EFFLUENT DISCHARGE

TPM LEVEL-1

ISO 22KCERTIFIED

2010ISO 14000

Water Conserver Award fromUNESCO


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2011- level 2 target

Thanks

Aradhana Softdrinks Maintenance Strategy

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