Sip project
- 1. IMPROVING OPERATIONAL EFFICIENCY AT HECTOR BEVERAGES PVT LTD A Summer Internship Project by S Prashant Reddy
- 2. INDEX • Company Profile • Assembly Line • Problem Statement • Data Collection Method • Data Analysis • Findings • Suggestions
- 3. COMPANY PROFILE • Hector Beverages Private Ltd is a manufacturer of Energy Drinks and Fruit Juices • Started by Neeraj Kakkar, Suhas Misra, James Nuttal and Neeraj Biyani in the year 2009. • It is currently operating with one plant in Manesar, Gurgaon. • It manufactures its products under the brands Tzinga and Paper Boat. • It currently exports its products to countries like Australia, United States of America (U.S.A), United Kingdom, Nepal, United Arab Emirates (U.A.E) and Canada.
- 4. CORE VALUES & QUALITY POLICY Core Values • Audacity • Rooting the Underdog • Integrity Quality Policy “We at Hector Beverages Private Limited as responsible corporate citizens shall conform to regulations and strive to improve the Product Quality, Food Safety and services continually through optimal Planning and Productivity in a environment friendly manner to achieve customer satisfaction.”
- 5. ISO CERTIFICATION • The company has been certified with ISO 22000:2005 in the year 2013. • It has been certified for raw materials, storage, dispatch and production (pasteurization) for the years 2013-2015. • It has been certified for serving non –carbonated ready to serve fruit beverages and non – carbonated fruit juice containing caffeinated beverages.
- 6. • Lemon Mint • Tropical Trip • Apple • Mango • Mango Strawberry PRODUCTS Energy Drink - TZINGA
- 7. • Aamras • Aam Panna • Jaljeera • Imli Ka Amlana • Jamun Kala Khatta • Kokum • Golgappe Ka Pani Fruit Juices - PAPERBOAT PRODUCTS
- 8. Sugar Dumping Unit Raw Syrup Tank Simple Syrup Tank Blending Tank-1 Blending Tank-2 Homogenizer Ready Beverage Tank -1 Ready Beverage Tank -2 Pasteurizer Filler Post Pasteurization Tunnel Cooler Tunnel Air Dryer-1 Air Dryer-2 Packaging Area Start End product ASSEMBLY LINE – FLOW CHART VIEW
- 9. PROBLEM STATEMENT – ISSUE TO BE RESOLVED “Decrease in the operational efficiency of the assembly due to the defects in packaging after the filler station.” • The defectives noticed listed were • to date coding not meeting the pre-determined standards • cap fitting of the pouches not done properly • leakages from the pouches • the pouches filled with low volume of the data OR no beverage filled in the pouches.
- 10. DATA COLLECTION METHOD • The data was collected on the defectives which occur in packaging after the filler station. The data was also collected about the production per hour. • The data about the defectives was collected by manual counting of the number of pouches at the end of the hour. • The data about production was collected from the product counter of the date coding machine. • In the second stage the data was collected on date coding defects which were related to misalignment, printing, visibility and absence of date coding. • This data was also collected through manual counting of the defects at the end of the hour. • The data collected during the tenure of the project was on hourly basis.
- 11. DATAANALYSIS • In the first stage data was collected about defectives that occur in filler station during the packaging of the beverage. • The defectives were as follows Date Coding not meeting the pre – determined standards. Cap fitting Not done properly. Leakages from the pouch. No beverage filled in the pouch. Beverage filled in the pouch less than the standard quantity.
- 12. • The readings collected for the defectives were as follows Defects (Per Day) Date Coding Cap Fitting Low Volume No Beverage Leakages Total 224 52 0 19 3 298 23 23 0 17 0 63 50 33 0 30 0 113 346 20 0 22 0 388 243 103 54 24 0 424 714 60 16 31 0 821 85 57 0 17 0 159 378 98 3 9 2 490 1265 177 5 98 2 1547 469 60 2 58 0 589 1010 79 103 27 2 1221 900 136 1 17 0 1054 452 76 102 18 3 651 44 26 13 7 0 90 117 215 6 23 0 361 464 127 12 70 2 675 6722 1284 357 456 29 8848 75.97 14.51 4.03 5.15 0.32
- 13. Date Coding 76% Empty Pouch 5% Low Fill 4% Cap Fitting 15% Burst Defects after Packaging Date Coding Empty Pouch Low Fill Cap Fitting Burst
- 14. • By using Pareto principle it was found out that date coding defects and low fill defects were the defectives which were responsible for the decrease in the operational efficiency of the assembly line. • In the second stage data was collected on various defectives that occur in date coding . They were Misalignment of the coding. Printing not being continuous. Date coding not properly visible due to ink marks. Missing of date coding on the pouch
- 15. Date Coding Defects (Per Day) Alignment Printing Visibility No Date Coding Total 109 3 0 57 169 503 159 82 236 980 116 49 9 30 204 38 3 1 40 82 67 0 1 32 100 150 2 5 128 255 13 0 0 3 16 94 99 9 38 240 323 72 12 97 504 34 89 7 42 172 377 104 26 136 643 276 73 69 291 709 2100 653 221 1130 4104 51.16 % 15.91 % 5.38 % 27.53 %
- 16. Alignment 51% Printing 16% Visibility 5% No Date Coding 28% Date Coding Defects Alignment Printing Visibility No Date Coding
- 17. • Pareto principle was used to find out the defects which were contributing more to the date coding defects. • They were found out to be Misalignment of date coding. Missing of date coding on the pouch. • A fishbone diagram was used to list out the various possible reasons for the occurrence of the defects.
- 18. Spouting of the pouches not done properly. Pouches inserted in the wrong direction Lack of synchronization between filler speed and print delay time Pouches inserted into the filler are exceeding the capacity of the Date Coding Machine Temperature in Filler Station Power Fluctuations Breakdowns Misalignment of Date Coding Alignment of the sensor being disturbed FISHBONE DIAGRAM FOR MISALIGNEMENT OF DATE CODING DEFECT
- 19. Pouches inserted in the opposite direction Lack of synchronization between filler speed and print delay time Failure of the sensor to detect the pouches Number of pouches inserted exceeding the capacity of date coding machine Breakdowns Power Fluctuations Missing of the Date Coding Alignment of the Sensor Being Disturbed FISHBONE DIAGRAM FOR MISSING OF DATE CODING DEFECT
- 20. FINDINGS• On an average 80 pouches were found to be defective in a batch of 3840 pouches processed in a hour. • Majority of the defects were date coding defects and they constituted 80 percent of the total defects. • The defects that were occurring in date coding were Misalignment of the date coding. Printing of the coding not being continuous. Date coding not properly visible due to ink marks on it. Date coding is missing on the pouches.
- 21. • The defects which were contributing more found out to be as misalignment and missing of date coding. • The root causes for the occurrence of misalignment in date coding were due to Lack of synchronization between filler speed and date coding machine. Alignment of the sensor being disturbed. • The root causes for the missing of date coding were Failure of the sensor to detect the pouch. Lack of synchronization between filler speed and date coding machine. Production helpers inserting the pouches in the wrong way.
- 22. SUGGESTIONS The suggestions which were given to the problem of misalignment were to • Make the position of the sensor fixed with the help of a plate or by any other means so that the position of the sensor does not get disturbed due to the pressure exerted by the beverage filling valve and nitrogen filling valve in the process of packaging. • Making sure that the flow is smooth and continuous so that there would less variability in the speed of the filler.
- 23. The suggestions which were given to the problem of absence of date coding were to • Doing an analysis to find out the reason why the sensor is failing to detect the pouches in certain instances and taking appropriate action. Frequent maintenance work of the sensor should be done to make sure that it is working in good condition. • The production helper who would be inserting the pouches should be cautious while inserting the pouches and a manual check should be performed before inserting
- 24. LEARNINGSThe things that I have learnt while working on the project and by observation are as follows • The practices that are to be followed in a food processing company to build quality into the product they manufacture such as checklists for every workstation, clean in place process etc. • The working of the assembly line in a beverage manufacturing company and the methods used to kill micro – bacteria present in the beverage. • The way in which the production is planned, flow of materials and type of production. • The problems associated if the assembly line is largely automated. • The scope for error and the importance of quality in a food processing industry. • The measures taken by the quality assurance team to provide good quality products to the customers. • The practices followed to store the products in the warehouse.