aradhana softdrinks maintenance strategy
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1
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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Aradhana Soft Drinks Company, PANIPAT, INDIA
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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Aradhana Soft Drinks Company, PANIPAT, INDIA
Our Brands
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Aradhana Soft Drinks Company, PANIPAT, INDIA
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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Aradhana Soft Drinks Company, PANIPAT, INDIA
Manufacturing ProcessBlow Moulding M/cs Filler Warmer
Sleever
LabellerEmpty Light Inspection
Taping M/cs
MIX Processor
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Aradhana Soft Drinks Company, PANIPAT, INDIA
Story of Transformation
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Aradhana Soft Drinks Company, PANIPAT, INDIA
Journey at Aradhana soft Drinks Panipat
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Aradhana Soft Drinks Company, PANIPAT, INDIA
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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Aradhana Soft Drinks Company, PANIPAT, INDIA
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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Aradhana Soft Drinks Company, PANIPAT, INDIA
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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Aradhana Soft Drinks Company, PANIPAT, INDIA
Manager Model Machine
Model Machine
BEFORE AFTER
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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Aradhana Soft Drinks Company, PANIPAT, INDIA
Lubrication Map of
Popular Circle
CoolingTunnel
BufferConveyor Sleever
HeatingTunnel Collecting
Table
Step 1
Before After Before AfterBefore After
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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Aradhana Soft Drinks Company, PANIPAT, INDIA
Step1
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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Aradhana Soft Drinks Company, PANIPAT, INDIA
Step-2Process Flow Chart
BEFORE AFTER
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-2Process Flow Chart
Forming of Team
Identification ModelM/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-2Process Flow Chart Special Type of Puller Made for Vent Tube ChangingVent Tube Chuck nut Made of Teflon
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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Aradhana Soft Drinks Company, PANIPAT, INDIA
Step-3Process Flow Chart
Forming of Team
Identification ModelM/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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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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Aradhana Soft Drinks Company, PANIPAT, INDIA
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
Identification ModelM/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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Aradhana Soft Drinks Company, PANIPAT, INDIABEFORE AFTER
THEME: Hot Water Tunnel after Filler Prepared to AvoidWastage of Water and Steam.
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Aradhana Soft Drinks Company, PANIPAT, INDIA
THEME: Preheating Hot Water Tunnel Prepared to avoidWastage of Water and Steam.
BEFORE AFTER
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Aradhana Soft Drinks Company, PANIPAT, INDIA
THEME: Prepared Auto Controller of Hot Water forPasturiser Water tank.
BEFORE AFTER
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Aradhana Soft Drinks Company, PANIPAT, INDIABEFORE AFTER
THEME: Repositioning of the Level Sensor to minimize thebottles loss.
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Aradhana Soft Drinks Company, PANIPAT, INDIABEFORE AFTER
THEME: Putting another valve closure to reduce thebeverage loss in 600mL.
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Aradhana Soft Drinks Company, PANIPAT, INDIABEFORE AFTER
THEME: Putting another valve closure to reduce the beverageloss in 600mL.
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Aradhana Soft Drinks Company, PANIPAT, INDIA
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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Aradhana Soft Drinks Company, PANIPAT, INDIA
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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Aradhana Soft Drinks Company, PANIPAT, INDIA
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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Aradhana Soft Drinks Company, PANIPAT, INDIA
BEFORE
THEME:GREASE NIPPLE FITTED OF CONVEYOR
GEARBOX
AFTER
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Aradhana Soft Drinks Company, PANIPAT, INDIA
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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Aradhana Soft Drinks Company, PANIPAT, INDIA
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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Aradhana Soft Drinks Company, PANIPAT, INDIA
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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Aradhana Soft Drinks Company, PANIPAT, INDIA
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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Aradhana Soft Drinks Company, PANIPAT, INDIA
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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Aradhana Soft Drinks Company, PANIPAT, INDIA
98 98.2799.4010099.44 100 100
0
25
50
75
100
N
o's
2005 2006 2007 2008 2009 Till
Jun
2010YearBenchMark Actual Target
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
2010YearBenchMark Actual Target
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Aradhana Soft Drinks Company, PANIPAT, INDIA
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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Aradhana Soft Drinks Company, PANIPAT, INDIA
2011- level 2 target
Thanks