Project REPORT ON

“To eliminate the Minor stops in overhead conveyor

UNDER GUIDANCE OF :Mr. Arul Ram (Mentor)

Mr. T.Rajya.Shesu (Guide)Mr. Pabitra Pradhan (Guide)

Submitted By :Naba Kishore Sarkar Regd No- 1011018011

Mechanical Brach ( Sec-C)ITER ( SOA University) BBSR

(Report submitted for the vocational training during sixth semester Electrical Engineering)

AT

Certificate

This is to certify that the project report entitled “To eliminate the Minor stops in overhead conveyor ” submitted by Mr.

Naba Kishore Sarkar, Regd No 1011018011 7th semester of the degree of Bachelor of Technology in Mechanical

Engineering at Institute of Technical Education & Research, Bhubaneswar is an authentic work carried out by him under

our supervision and guidance in the summer training conducted by HINDUSTAN COCA COLA BEVERAGES PVT

LTD. To the best of our knowledge, his conduct was satisfactory.

Date: Place: Khurda

Mr. Mohan SinghFactory Manager HCCBPL , Khorda

I would like to convey my sincere gratitude to the director and management of HINDUSTAN COCA-COLA BEVERAGES PRIVATE LIMITED,KHURDA for providing me to undertake industrial training from 20.05.2013 to 20.07.2013.I am very thankful to Mr. Mohan Singh , Factory Manager(HCCBPL), for his kind support and encouragement during the training period .I would also like to extend my thankfulness to other officers namely Mr. Md. Rumman (Manager OE), Mr. Arul Ram KB(Manager TPM), Mr. Mathurananda Nayak(Incharge Shipping), Mr. N.K Dubey(Manager Safety) & all other officials of HCCBPL khorda who have given their full co-operation during my entire training tenure.

I wish to thank my supervisor Dr. D.N.Thatoi , Prof. and Head Mechanical Engineering Department, ITER Bhubaneswar andI am sincerely thankful to Dr. H.C.Das, Prof. Mechanical Engineering Department, ITER Bhubaneswar for his valuable and kind suggestions.

I am extremely grateful to Mr. T.Rajya.Sheshu (Production Manager ) HCCBPL for his persistent support and advice during the project work. I am also thankful to Mr. Pabitra Pradhan (Team Leader in Production RGB Line), HCCBPL Khurda for his help during project work.

Special thanks to my family members, without their blessings and support, I could not have reached this destination. Last but not the least, I wish to place my deep sense of thanks to my friends especially to Mr. Debashis, Line Executive(RGB) and Mr. Amar pahi for their cooperation and critical suggestion during my project work and studies.

Place: Bhubaneswar Naba Kishore sarkar

Acknowledgement

Declaration

We do hereby declare that this project entitled,” To eliminate the minor stops in Overhead conveyor” has been carried out by us in coordination with our project supervisor Mr.T.Rajya Sheshu for the fulfillment of our summer training. Any other institution for financial rewards or any other purpose has not submitted this work. We do further declare that the fact of data and figures presented in the project are to the best of our knowledge & belief.

Place: HCCBPL KhurdaDate:

Arul Ram(Planning Manager)

Pabitra Pradhan(Team leader Production Dept)

Contents

1. Project charter2. Introduction3. Process mapping4. Downtimes check list5. Downtimes chart6. Problems7. Fish bone analysis8. Causes 9. Facts10. Improvement a. Sensor b. Initial loading bay flush11. Dry floor12. Fork lift analysis chart

Project Name: Project #: Project Start/End Dates:

To eliminate the Minor stops in overhead conveyor

  30 May 2013 Project Lead: Naba kishore sarkar Executive Sponsor: Arul RamUnder Guidence of: Project Costs: (include required capital, expenses)

T. Rajya . SheshuPabitra Pradhan

- /- - Expenses:

  

Mission/Project Overview:

To find out the main problems behind the downtimes of over head conveyor

  

Objectives: (include beginning & ending KPI's) Net Benefits:

To improve SLE of RGB from current level Reduce downtimes                                          

In Scope: OE Tools to be used: Out of Scope:                  RGB overhead conveyorAssumptions: Risks & Constraints:Number of product changes will remain same or less than current ratio.

 

Project Milestones: Dependencies:Define : 30 June 2013  

Measure : 15 July 2013Analyze: Causes of downtimes    

Improve : Reduce the downtimes    Control : Break down    

Project Lead Time: (Total time required to implement) 2Months Other Key Stakeholders & Areas Affected:   Approvals:Project Lead: Naba Kishore Sarkar Date:  Area Lead:   Date:  Finance:   Date:  Executive Sponsor/Steering Committee:  

Date: 

PROJECT CHARTERList of downtimes of overhead conveyor

Introduction :HISTORY OF COCA-COLA COMPANY:-Coca-Cola is a carbonated soft drink sold in stores, restaurants and vending machines in every country except Cuba & North Korea. Dr. John Smith Pemberton, a pharmacist from Atlanta, Georgia developed the syrup that would become the basis for Coca-Cola. The Coca-Cola formula and brand was bought in 1889 by Asia Griggs Candler who incorporated the Coca-Cola company in 1892 in Atlanta, Georgia. The company offers more than 500 brands in over 200 countries or territories and serves over 1.7 billion serving each day. The company only produces syrup concentrate which is sent to various licensed bottlers throughout the world. The bottlers produce finished product in cans and bottles from the concentrate in combination with filtered water and sweetners and sell, distribute the products in various retail stores and vending machines.

HINDUSTAN COCA-COLA BEVERAGES,PVT.LTD:-Hindustan Coca-Cola beverages is the largest bottling investment group (BIG) of the Coca-Cola company in India. It has 24 bottling plants in various states spread across India.

VISION:-To make every Indian’s first choice of refreshment available within easy reach.

MISSION:-To build a consumer-driven, customer-focused, profitable, sustainable & society responsible business in India.

PRODUCTION( HCCBPL produces) :--Sparkling beverages (Coca-Cola, Diet coke, Thumps up, Sprite, Limca ,Fanta, Soda) -Still beverages [ maaza, minute maid (pulpy orange, nimbu fresh, mango 100% juices range of fruit flavoured drinks)]-Water (Kinley, Bonaqua)

ACHIEVEMENTS & AWARDS:-HCCBPL is encouraged in its drive for excellence in all spheres by the recognition received from various stakeholders such as •“Best water management award” by CII (2006,2007,2008,2009)•“Pollution control excellence award” by SPCB, Odisha (2005)•“Best employer award” (2005) & “Best environment practice award” (2012) by APPCB, Andhra Pradesh.•“Golden peacock award” (2006,2008,2009)•“Best employer award” for employing “Physically Challenged” personnel & Best organization of Uttar Pradesh (2006) by govt. of Uttar Pradesh.•National safety council award by govt. of India. Plant description :The plant consists of six production lines along with two water treatment plants and one effluent treatment plantThe production lines are :-Maaza line(RGB)140 BPM PET(CSD)Kinley line600 BPM PET(CSD)Tetra pak(Maaza/Minute maid)RGB(CSD)

Maaza line(RGB) :-•This line produces “Maaza” which is a juice based product from Coca-Cola industry.•Glass bottles consisting 200ml/250ml beverage are being produced here.•This line produces 600 bottles per minute.

140 BPM PET(CSD):-This line produces carbonated soft drinks like “Coca-Cola”, “Thums up”, “Fanta”, “Limca” & “Sprite”.PET bottles of 2ltr,2.5ltr,1.25ltr are being produced in this line.The capacity of this line is 140 bottles per minute.

600 BPM PET(CSD):-•This line produces carbonated soft drinks like “Coca-cola”, “Thums up”, “Fanta”, “Limca” & “Sprite”.•PET bottles of 400ml,500ml,600ml are being produced here.•The capacity of this line is 600 bottles per minute.

Tetrapak:-•This line produces “Maaza” and “Minute maid Mango”.•Each pack contains 200ml by volume.•Line capacity is 400 packets per minute.

Kinley :- •ThiThis line produces carbonated soft drinks like “Limca”, “Coca Cola”, “Thums up”, “Sprite” & “Fanta”.•This line produces 300ml and 200ml glass bottles.•Capacity of this line is 600 bpm.•line produces packaged mineral drinking water.•Capacity of each bottle is 1 ltr by volume.•The plant produces 140 bottles per minute.•s line produces packaged mineral drinking water.•Capacity of each bottle is 1 ltr by volume.•The plant produces 140 bottles per minute.

RGB (CSD) :-•This line produces carbonated soft drinks like “Limca”, “Coca Cola”, “Thums up”, “Sprite” & “Fanta”.•This line produces 300ml and 200ml glass bottles.•Capacity of this line is 600 bpm.

Overhead Conveyor is a form of Conveyors consisting of a continuous chain running beneath a continuous, stationary, flanged rail. Individual carriers spaced equidistant along the length of the conveyor are suspended from the chain. The chain pulls the carriers. Vertical support is derived from the fact that the carriers are also connected to a small trolley with wheels that roll cross sections, trolleys and carriers. A few common carriers include a tray, platform or simple hook. A less common alternative to the chain drive is a worm drive. Overhead or ceiling hung conveyor is often used to maximize space, sort, buffer, and distribute, and is one of the most economical methods of conveying while maximizing floor space.Overhead conveyors which move automatically through the production process on a rail are used for the transportation of many components. A certain minimum distance is required so that components do not collide with each other during the transport.

The overhead conveyor comprises a main track and a branch track connected to the main track in a switch point, the tracks having a shape of a box-like beam with a longitudinal slit in its bottom flange for suspending a trolley carriage, the carriage supporting a rocking lever having at its ends guiding rollers, the operation of the switch point being safeguarded via tiltable tongues arranged on the lower flange of the track and cooperating with slide shoes provided on the ends of the rocking lever, and by means of locking rails attached to the side walls of the track to lock the rocking lever in the desired angular position; the ends of the rocking lever further support safety noses each having an inclined surface of a length sufficient for bridging the gap between the ends of the inclined tongues and the beginning of the locking rail when the slide shoe still engages the end portion of the safety tong.

Process mapping

Empty yard( Loading Bay)

Slope conveyor(upward)

Slope conveyor(downward)

Horizontal

Spiral conveyor

Horizontal

Uncaser

SL. No DATE SHIFT PROBLEM ACTION TAKEN ROOT CAUSE DOWNTIME(mins)

1 30-May C chain link bend 4 Link cutted over age & lack of lubrication 4

2 31-May A chain out Chain shortened wear & tear 2

3 31-May B broken crate problem

crate released and conveyor restarted

broken crate stucking 4

4 1-Jun A chain out sporcket changed sprocket damage 14

5 1-Jun A spiral conveyor strip damage strip was replaced more chain

slackness 4

6 1-Jun chain out (slope conveyor) Chain shortened Worn out due to

lack of lubrication 10

7 2-Jun B chain out sprocket changed Sprocket damage 8

8 2-Jun spiral conveyor strip damage new strip fitted Due to life span 4

9 3-Jun A chain out cutted and fitted wear & tear 12

10 4-Jun B chain out Chain shortened Worn out due to lack of lubrication 14

11 5-Jun A chain out from idler new modified collar was fitted heavy dirt particles 8

12 5-Jun B chain out sprocket changed Sprocket damage 2413 7-Jun C chainout Chain shortened wear & tear 1214 8-Jun C chain out Chain shortened lack of lubrication 6

15 11-Jun B OHC stops sensor was cleaned sensor problem due to heavy rain 4

16 11-Jun C OHC trip reset and restarted Frequent start and stop 3

17 12-Jun B OHC chain slip sprocket changed Sprocket damage 4

18 12-Jun A chain out repaired Wear striped damaged 24

19 13-Jun B chain out repaired Wear striped damaged 6

20 13-Jun C sensor problem sensor was cleaned sensor problem due to heavy rain 4

21 14-Jun A sensor problem sensor was cleaned sensor problem due to heavy rain 20

Downtimes check list

1) Chain out from sprocket2) Motor trip3) Chain link bend4) Cable short5) Channel break6) Collar roller damage7) Bearing damage8) Strip damage (spiral

conveyor)9) Sensor malfunction10)Broken crate

Problems faced in overhead conveyor (Top ten)

Classified - Internal use

Overhead

conveyor

stops

Technical skill

Training

Broken crate Sensor malfunction

Cable short

Chain link bend

Strip damage in spiral

conveyor

Channel break

Chain out from sprocket

MATERIAL

METHOD

MACHINE

MAN

Heavy dirt particles & heavy rain

Motor tripped

Fishbone analysis for Overhead conveyor failure

Lack of lubrication

Lack of awareness

Fluctuation of voltage

supplyOver load &

bearing failure

Lack of lubrication & life

span of strip

Frequent use & lack of

lubrication

Bearing damage

Lack of lubrication Wear and tearOver load ( sensor malfunction)Sprocket worn outHeavy dirt particlesFrequent start & stop ( Fluctuation

of power)Broken crate stuck Life span

Causes of chain out

Classified - Internal use

* Stainless steel flat chains slides over plastic plates to get less friction and obtain better slide.

Improvement to reduce downtimes

Before After

No protection from rain New SS cover for sensor to avoid heavy rain

Improvement to reduce downtimes

By this modification heavy dirt particles coming with crate will get flushed & SS cover will avoid water contact with motor.

Pictures captured during breakdown

Strip broken on spiral conveyor SS flat chain link broken

Classified - Internal use

BEFORE AFTER

Classified - Internal use

BEFORE AFTER

Classified - Internal use

Classified - Internal use

BEFORE AFTER

Day 2 Fork Lift No : 14 (Double capacity , battery operated )

Date : 25 May 2013

Driver Name : Mr Kesar Gajendra

Shift: A

Sl. No. Time Workdone1 Workdone2 Workdone3 Workdone4 Remarks

Total Total

Palates

cases

1 6:00-7:00

Was there in ware house till 6:30am

Engine starts at 6:30am

Shifting of palates till 7am NA NA NA NA

2 7:00-8:00

At 7:00 started working in ware

house7:55-8:00 No work NA NA

Only shifted few palates which were not fully

loaded11 581

3 8:00-9:00

Switched off engine at8:15 Went for breakfast NA NA Lifted few fully loaded

palates 3 146

4 9:00-10:00 Engine starts at 9:00 Went to maintenance

yard at 9:15Engine switched off for battery change NA Did sourcing work 14 856

5 10:00-11:00

At 10:02 engine starts after battery

changed.10:08- 10:10 took rest 10:30-10:35 roamed

without any work10:35-10:55 again

took rest

Here he worked in production, sourcing,

dustbin shifting etc19 976

6 11:00-12:00

Worked in sourcing of empty RGB

11:40-11:50 mango pulp drums shifting

Worked for production This 1hr he worked at a

good speed 74 ####

7 12:00-13:00 NA NA NA NA NA NA NA

8 13:00-14:00

NA NA NA NA NANA NA

Initial running hour= 10107 Total no. palates =121

Final running hour =10111.5 Total no. cases=6079Total running hour= 4.5hr BY- Naba Kishore Sarkar

Participated in taking the observation for determining forklift efficiency.

Conclusion

A conveyor system is a common piece of mechanical & electrical handling equipment that moves materials from one location to another. Conveyors are especially useful in applications involving the transportation of heavy or bulky materials.

Introduction :