at : hindustan coca hccbpl by: amit saha - society of ... 2/safety...about hccb • hccbpl is the...
TRANSCRIPT
Fleet & Road Safety Management
Program
at :
Hindustan Coca – Cola Beverages Pvt. Ltd
HCCBPL
By:
Amit Saha Chief Sustainability Officer
About HCCB
• HCCBPL is the largest bottling partner of The Coca-Cola Company in India
• Part of The Coca-Cola Company’s Bottling Investments Group (BIG) and responsible for the
manufacture, package, sale and distribution of beverages under the trademarks of The Coca-
Cola Company.
• 25 Manufacturing Locations
• 67 Warehouse (Owned or operated through C&F)
• 1613 nos. Own Fleet
Classified - Internal use
Why focus on Fleet Safety?
Current Situation of Road Safety In Country
• India has the highest number of people killed in Road Accidents
• Easy to get license in the country.
• Low focus on Defensive Driving
• Lack of regulatory enforcement
• Drink and Drive is rampant
Challenges –
For HCCBPL Owned Fleet
• Ageing fleet
• 70+ different Models
• High seasonality factor – spot hiring
• Very High Attrition among Drivers
• Drivers managed by C&F
3rd Party Transportation
• High seasonality
• High no. of Transporters
• Untrained drivers and High Attrition
• 100+ Vehicle Models
Classified - Internal use
Metros - 60% Non-Metro – 40%
Total Company Owned Fleet : 1613 Operating with Distributors : 134 Operating with us : 1479
Non-Functional : 102 (all > 10 yrs age) – 6.3% of fleet is non-functional
Functional Fleet : 1511 (HCCBPL – 1396 + Distributor – 115)
Objective:
Classified - Internal use
• 100% safety Compliant
• Aesthetically good
• Optimal capacity utilization
• Lowest fuel bill (and reduced CO2 emissions)
• 100% uptime (and focus on PM)
Method:
• Robust Preventive Maintenance
• Upgrade fleet Hardware
• Behaviour Training of Drivers / DMCs
• Use of technology to monitor behavior change
• Improve crash reporting
• Awareness campaigns
• Palletisation and Standardisation
• External Checks and Validations
Fleet Management Program
Classified - Internal use
Classified - Internal use
Vehicles
Processes
People
Fleet Maintenance Planning: Daily Maintenance Checklist Yearly Maintenance schedule and Statutory Compliance Schedule
Fleet Refurbishment Planning: • Safety Hardware Corrections •Schedule timelines for Body repair, painting & Graphics to enhance image of coke
Manpower Planning: •Standardizing manpower based on number of Vehicles •Identify Gaps & take corrective action .
Capability Building : •Provide training to the manpower on new technology adopted by Vehicle manufacturers.
Maintenance:- • Plan shift wise working for maintenance and repair activates • Documentation for maintenance and repair activities 1.Vehicle Master File 2. Vehicle Complaint/Corrective action3. Vehicle History Card
Spare Parts:- 1.Identify Critical Items 2. Maintain minimum Inventory level 3. Develop of Vendor Base
KPI monitoring :- 1. Vehicle Uptime 2. Preventive Maintenance Compliances 3. Maintenance cost 4. Hiring cost 5. Running cost of vehicle 6. Crash Rates
Daily Fleet Activity
Classified - Internal use
Preventive Maintenance of Own Vehicles
Classified - Internal use
• Daily Checklist:
TO BE PASTED INSIDE DRIVER CABIN
• Checklist with 21 points as per manufacture recommendation
• Time required 10 minutes per truck (repair time extra)
• Person required one capable mechanic with one helper in one shift
Found correct : OK
Found defective/ repaired :
Found defective / not repaired : X
• Safety related checkpoint is to be rectified at the time of checking and on other points
if spare part is available in stores than on same day otherwise within two days.
• Monthly Checklist: Depending on no. of vehicles in the depot, schedule will be prepared for
monthly checks.
• Yearly Checklist: This is fitness and oil change maintenance related checks. schedule will be
prepared based on number of vehicle required to go for fitness each month.
Preventive Maintenance
Daily Checking - 21 Points
Mechanic - 1
Helper - 1
Standard Time - Checking : 15 min
Correction - Extra based on nature of defect
Monthly Checking – 36 Points
Mechanics - 1
Auto Electrician – 1
Helper - 2
Standard Time Checking : 2.5 hrs
Correction – Extra Based on nature of defect
Annual Checking - 53 Points
Sr. Mechanic - 1
Mechanic - 1
Auto Electrician - 1
Helper - 3
Standard time Checking : 8 hrs
Correction - Extra Based on nature of defect
Health Check up
Classified - Internal use
Fleet Safety Hardware Upgrade
Classified - Internal use
1. Speed Governors
To control the speed of our vehicles on Road,
speed governors are being provided with
speed limiter of 60 KMPH
Phase 1, Vehicle attached to:
• depot located outside the city limit
• Vehicle operating on highway
• Primary vehicle.
• 670 Vehicle fitted with Speed Governor.
• Plan to cover 100% vehicle by exit 2013
2. Advantage
a)Tamper proof
b)Road Speed is controlled.
c)Reduction in number of accidents.
d)Increase in safety on road.
Fleet Safety Hardware Upgrade
Classified - Internal use
1. Retractable 3 point Seat Belt
To secure the occupant of a vehicle against
harmful movement that may result during a
collision or a sudden stop
Old vehicles were not provided with seat belts
or they were removed in past.
• 1200 Vehicle fitted with Retractable Seat-
belt.
2. Method
• 70 different models
• SOP developed for retro-fitting of seatbelt for
driver, co-driver and loader in all models.
• Responsibility of supplying & fitting with
Eicher and Seat belt procured from OEM
SOP for Seat Belt Fitment
Fleet Safety Hardware Upgrade
Classified - Internal use
1. GPS for Plant to Depot/Distributor Trucks
To track the route compliance, TAT, and
behaviors like over-speeding, sudden
acceleration, braking, stoppages and
counsel/correct driver’s behaviour through
Driver Management Centers (DMC).
• 750 Vehicle fitted with GPS (including
3rd party transportation)
2. Method
• Integration of vehicle location (GPS
location data from vehicle) with trip data
(as recd. from Coke ERP) and presented in a
single user interface
• Geo Coding of all coke source (Plant,
Depot) & destination (Depot and
Distributors)
Dashboard Mounted GPS Unit
Safety Dashboard for GPS Vehicle
Palletisation of Fleet
Classified - Internal use
1. Palletisation
• Ensure better space utilisation
• 100% legal & safety compliance
• Loading-unloading with FLT (minimise
man involvement)
• Standard body design
• GPS for palletized dedicated vehicles
2. Method
• Selection of multiple manufacturers
and Vehicles
• In-house designing of vehicle body
• 100% Compliant to CMVR Rules
• Fitted with all Hardware as per HCCB
Guidelines
• Stronger Structure with Light Material
resulting in more payload
• High quality OE specification paint
which has longer life and excellent
finish.
Open Pallet Design on 32 ft Eicher Truck with roll up shutter.
Defensive Driving Training
Classified - Internal use
1. Defensive Driving Training
On Wheel Driver training by external agency &
DMC counselors in:
a) defensive driving techniques,
b) Practical Assessment of Drivers and
c) Certification for drivers at different
locations across India
SOP Defined by HCCB
2. Update
a) Covered approx 1200 drivers in 2014
on 4 wheeler DDT by DMC counselors
Crash Reporting & Accident Investigation
Classified - Internal use
1. Crash Reporting
• We can’t manage, what we can’t
measure
• SOP for crash reporting implemented
in all depots.
• No. of crashes linked with spares
issued/ major denting/ painting jobs
2. Accident Investigation
• Training workshop for all Zonal Safety
Managers & Fleet Executives
• All fatality accidents are investigated
by external agency
• All fatality accident CAPA discussed in
APEX committee meetings.
SOP for Crash Rate reporting
RESPONSIBILITY
Report any damages to the vehicle to Fleet in-
charge or Stores – In charge during 21 point
checklist, vehicle inspection or verbal reporting.
Is the damage serious
and requires denting/
painting/ fabrication
work?
Report as Near Miss in
Incident Register kept at
Security
Yes
No
FILL THE INCIDENT IN CRASH
FORMAT REGISTER before signing the
store requisition slip.
All drivers/fleet
maintenance/security
Fleet in-charge
or Stores in-
charge
Fleet in-charge or
Stores in-charge
Fleet in-charge or
Stores in-charge
Depot In-charge
Does it require
replacement of any
component on account
of accident? For eg..
Broken headlamps,
mirrors, etc
Yes
No
Issue the component after
signing store requisition slip.
Report total crashes, no. of vehicles to
ZSMs & Zonal Fleet Managers on
monthly basis
Road Safety Week
Classified - Internal use
1. Road Safety Week
• In month of January, observed across
HCCBPL locations both manufacturing
& Non-Manufacturing
2. Key Activities
• DDT Sessions
• Reflective Tape distribution
• Vehicle Check camps
• ‘I AM A SAFE DRIVER’ campaign
• Distribution of pamphlets
• Focused TBTs everyday
• Quiz and Slogan competitions
• Reward and Recognition
• Awareness session for employees on
Speed Governors & Vehicle Tracking
System
• School & Community Engagements
TBTs on Road Safety
Safety Badges for employees wearing Seat Belts
DDT for Transporter Drivers, Karnataka
Reflective Tapes for Vehicles at Nemam, TN
Mystery follow-ups at DMC locations
External Audits/ Checks
Classified - Internal use
1. Comprehensive external audits
• Annual Fitness Check by external
agency for all dedicated vehicles.
• 85 critical point check for all vehicles
• Safety, Aesthetics, Legal, Mechanical
categories.
2. Method
• Done for 1100+ vehicles
• Vehicle categorised as correctable or
NO Gos (to be scrapped)
• Action plans for zones for fleet
correction
87
324
508
99
211 229
518
60 19
73
310
616
<7.5 8 9 10
Fleet Audit Summary Safety Index Aesthetics Index Mechanical Index
Monthly Fleet correction Monitoring
Transporters Capability Workshop
Classified - Internal use
• 1 day Workshop done in 8 zones covering 87 Transporters • Followed up Audits and Action Planning
What is Driver Management Centre?
Classified - Internal use
Key Activities
DMC: Zero Road Incident
Safe Driver
Safe Vehicle
Manage Route Risks
by GPS
Post Journey Counseling with
GPS
Pre Journey Counseling &
JRM
Vehicle Check & Integrated Gate
Pass
Mystery Follow-ups
Tool Box Talks with Drivers
Reward & Recognition
Disciplinary Matrix
Live Alerts & Phone Calls
Fatigue & Rest Monitoring
Counselor Quality Check and Driver
Surveys
Drink and Drive Monitoring
Meetings with Transporters
Classified - Internal use
Driver Management Centre – Pre Journey Counseling
Explanation of Journey Risk Management
Alcohol Check
Mystery follow-ups
Classified - Internal use
Driver Management Centre – Post Journey Counseling
GPS Trip Report
Fatigue Index
Live Alerts
Classified - Internal use
Driver Management Centre – Vehicle Check
Detailed Vehicle Check – 32 Points
Integrated Gate Pass
Classified - Internal use
Driver Management Centre – Other Activities
Transporter Capability Weekly Star Driver Shift-wise TBTs
Disciplinary Matrix
DDT
Medical Checks
Glimpses of DMC activities
Day & Night Shift TBTs
Simulation & case Studies
Medical & Eye check Ups Blood Alcohol Level Check
Driver’s Day Observance
• Why Driver’s Day?
• Cake cutting
• Quiz
• Hand wrestling
• Sack race
• Poster Competitions
• Mimicry Competition
• Pledge taking
• JRM
• Group photograph with Drivers
Classified - Internal use
HCCBPL
Community Engagements
on Road Safety
Vijetha HighSchool
Key Activities: 1) Interaction with students on current Road Scenario & discussing their experience – relating it
to need for Road Safety Education 2) AV session by DMC Team 3) Quiz & prize to winners given by School Head Master - Mr. Umashankar
Zila Parishad High School, Peddavadalapudi
Nagarjuna School
Zila Parishad High School, Atmakuru
Quiz & Prize Distribution by School Headmaster – Mr. C H George & other School Teachers, followed by Group Photographs
Peddavadalapudi Grampanchayat Office
Q & A session and Group Photograph with Gram Panchayat members & Sarpanch - Mr. C H Venkateshwar Rao