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Support from Autonomous

Maintenance for Break Down


Reduction

Surender Kumar Sharma


General Manager (North Operations)Pepsico India
Aradhana Soft Drinks Company, PANIPAT, INDIA

PEPSICO
Pepsico World wide

PepsiCo India

FY09 revenues of $ 60 billion,


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

3RD Largest FMCG company in


India

2ND Largest Food and


Beverage company in the
World

30% Growth in FY 09

Over 180,000 professionals in


200 countries and

Aradhana Soft Drinks Company, PANIPAT, INDIA

42 Plants including snacks

Our Brands

Aradhana Soft Drinks Company, PANIPAT, INDIA

Site Information
PLANT ESTABLISHED IN 1991
ACQUIRED BY PI IN 2003

Plant area-10 Acres ( 39452 Sq. mt )


Lines

Rated Capacity

CSD GRB
CSD PET MS
CSD PET SS
CSD BIB
Slice GRB
Slice HY PET

550 BPM
80 BPM
300 BPM
100 BPM @ 12 L
200 BPM
73 BPM

TOTAL

1203

Full Time Employees


Managers 6
Executives - 34
Associates - 116
Aradhana Soft Drinks Company, PANIPAT, INDIA

Manufacturing Process
Blow Moulding M/cs

Filler

MIX Processor

Empty Light Inspection

Taping M/cs

Aradhana Soft Drinks Company, PANIPAT, INDIA

Warmer

Sleever

Labeller

Story of Transformation

Aradhana Soft Drinks Company, PANIPAT, INDIA

Journey at Aradhana soft Drinks Panipat

Aradhana Soft Drinks Company, PANIPAT, INDIA

Pg No.17

TPM ORGANISATION
Corporate Steering Committee

Pillar Sub
Committee

Lead Plant
Manager
TPM Secretariat
Plant Manager

Jishu Hozen
Kobetsu Kaizen
Planned
Maintenance

Departmental manager

Steering Committee

Line FPRs
(First person responsible)

Departmental Committee

Associates

Quality
Maintenance
Initial Flow
Control
Office TPM

Circles

Education &
Training
Safety Health &
Environment

Aradhana Soft Drinks Company, PANIPAT, INDIA

Targets and Goals

Aradhana Soft Drinks Company, PANIPAT, INDIA

Master Plan

Aradhana Soft Drinks Company, PANIPAT, INDIA

Autonomous Maintenance

Aradhana Soft Drinks Company, PANIPAT, INDIA

Approach
Forming of Team

Identification Model
M/CS

Circle Name:- Golden Lion


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

Forming & Performing


of 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

Aradhana Soft Drinks Company, PANIPAT, INDIA

STEP ZERO ACTIVITIES


 Each Circle Leader and Circle members were given
both 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

White Fuguai Tag

Red Fuguai
Tag

Closed By Maintenance
Aradhana Soft Drinks Company, PANIPAT, INDIA

Closed By Operator

Customization of
Tool Board

Model Machine
Forming of Team

Identification Model
M/CS

Forming & Performing


of 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

Aradhana Soft Drinks Company, PANIPAT, INDIA

Manager Model Machine

BEFORE

AFTER

Step 1
Forming of Team

Identification Model
M/CS

Lubrication Map of
Popular Circle

Forming & Performing


of CLITA & Tagging

Heating
Tunnel

Collecting
Table

List of Hard to CLITA &


Sources of Contamination

Countermeasure for Hard to CLITA


& Sources of Contamination

Buffer
Conveyor

Sleever

Cooling
Tunnel

Making of Kaizens
& OPLS

Forming of CLITA Standard


& Results

General Inspection

Before
Aradhana Soft Drinks Company, PANIPAT, INDIA

Before
After

After
Before

After

Step1
Forming of Team

Identification Model
M/CS

Forming & Performing


of 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

Aradhana Soft Drinks Company, PANIPAT, INDIA

Step-2
Process Flow Chart
Forming of Team

Identification Model
M/CS

Forming & Performing


of 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

BEFORE
Aradhana Soft Drinks Company, PANIPAT, INDIA

AFTER

Step-2
Process Flow Chart
Forming of Team

Identification Model
M/CS

Forming & Performing


of 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

Aradhana Soft Drinks Company, PANIPAT, INDIA

Aradhana Soft Drinks Company, PANIPAT, INDIA

Aradhana Soft Drinks Company, PANIPAT, INDIA

Step-2
Process Flow Chart
Forming of Team

Identification Model
M/CS

Forming & Performing


of 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

Aradhana Soft Drinks Company, PANIPAT, INDIA

Vent
Tube
ChuckMade
nut Made
of Teflon
Special
Type
of Puller
for Vent
Tube Changing

Step-3
Process Flow Chart
Forming of Team

Identification Model
M/CS

Forming & Performing


of 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

Aradhana Soft Drinks Company, PANIPAT, INDIA

Pg No.46

VISUAL CONTROLS
For ease of Inspection and early detection
For checking abnormalities in critical process parameters.

Jishu -Hozen visual controls


Aradhana Soft Drinks Company, PANIPAT, INDIA

Step-4
PREPARATION

TRAINING AIDS

Forming of Team

Working
Model

Identification Model
M/CS

Cutsections

OPL
Forming & Performing
of CLITA & Tagging

TRAINING

Training

List of Hard to CLITA &


Sources of Contamination

Manuals

OJT

Countermeasure for Hard to CLITA


& Sources of Contamination

General

Fastner
4
Mc. Condition

Making of Kaizens
& OPLS
safety

Forming of CLITA Standard


& Results

Aradhana Soft Drinks Company, PANIPAT, INDIA

Actual

Drive

Training Model
Lubrication

AUDIT
Pneumatics

Electrical
BM
Target

General Inspection

3
2
1
0

GENERAL
Inspection
INSPECTION
Sheets

Hydraulics

OEM Training

THEME: Hot Water Tunnel after Filler Prepared to Avoid


Wastage of Water and Steam.

BEFORE

Aradhana Soft Drinks Company, PANIPAT, INDIA

AFTER

THEME: Preheating Hot Water Tunnel Prepared to avoid


Wastage of Water and Steam.

BEFORE

Aradhana Soft Drinks Company, PANIPAT, INDIA

AFTER

THEME: Prepared Auto Controller of Hot Water for


Pasturiser Water tank.

BEFORE

Aradhana Soft Drinks Company, PANIPAT, INDIA

AFTER

THEME: Repositioning of the Level Sensor to minimize the


bottles loss.

BEFORE

Aradhana Soft Drinks Company, PANIPAT, INDIA

AFTER

THEME: Putting another valve closure to reduce the


beverage loss in 600mL.

BEFORE

Aradhana Soft Drinks Company, PANIPAT, INDIA

AFTER

THEME: Putting another valve closure to reduce the beverage


loss in 600mL.

BEFORE

Aradhana Soft Drinks Company, PANIPAT, INDIA

AFTER

THEME: Cap Stopper installed to avoid inverted cap


entering into Capper Line 2 filler.

BEFORE

Aradhana Soft Drinks Company, PANIPAT, INDIA

AFTER

THEME: Air knife removed by using the blower air for


removing the water particles from bottle.

BEFORE

Aradhana Soft Drinks Company, PANIPAT, INDIA

AFTER

THEME:CARBO-COOLER MIXING PUMP EARTHING


DONE

BEFORE
Aradhana Soft Drinks Company, PANIPAT, INDIA

AFTER

THEME:PROPER PVC GLAND FITTED

BEFORE
Aradhana Soft Drinks Company, PANIPAT, INDIA

AFTER

THEME: Extra conveyor support SS clamped cut.

BEFORE
Aradhana Soft Drinks Company, PANIPAT, INDIA

AFTER

THEME:FILLER TABLE TOP PROFILE GZC 107 NEW


CHANGED

BEFORE
Aradhana Soft Drinks Company, PANIPAT, INDIA

AFTER

THEME:MOTER DIRECTION INDICATED

BEFORE
Aradhana Soft Drinks Company, PANIPAT, INDIA

AFTER

THEME:SU PIPE NYLON BLACK SUPPORT FITTED

BEFORE
Aradhana Soft Drinks Company, PANIPAT, INDIA

AFTER

THEME:GREASE NIPPLE FITTED OF CONVEYOR


GEARBOX

BEFORE
Aradhana Soft Drinks Company, PANIPAT, INDIA

AFTER

THEME: CARBOCOOLER S.C.FM ROTA METER


CHANGED

BEFORE
Aradhana Soft Drinks Company, PANIPAT, INDIA

AFTER

THEME:DRAIN LINE WELDING CRACKED

BEFORE
Aradhana Soft Drinks Company, PANIPAT, INDIA

AFTER

THEME:SU PIPE NYLON SUPPORT FITTED

BEFORE
Aradhana Soft Drinks Company, PANIPAT, INDIA

AFTER

THEME:IN CARBOCOOLER U.V LIGHT PRESS. GAUGE


FITTED IN REVERSE DIRECTION.

BEFORE
Aradhana Soft Drinks Company, PANIPAT, INDIA

AFTER

Aradhana Soft Drinks Company, PANIPAT, INDIA

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

Aradhana Soft Drinks Company, PANIPAT, INDIA

Aradhana Soft Drinks Company, PANIPAT, INDIA

Total Plant Productivity


9

8.40
8

8
5.47
6

6.86

6.11

7
5.53

6.05

%
4
3

Total Tag Compliance

100

1
0
2005 2006 2007 2008 2009

BenchMark

Actual

Target Year

92
79

80

Till
Jun
2010

64

87

92 90

68

60
%
40
20
0
2005 2006 2007 2008 2009

B e nc hM a rk

Aradhana Soft Drinks Company, PANIPAT, INDIA

A c t ual

T a rge t

Year

Till
Jun
2010

Skill Level (Operator)


4

Average Level (1 to 4)

3.2

3.23

2.88

2.61

3.60

2.21
2

2.00

Internal Trainer
1

15

15
12
2005 2006

BenchMark

2007

Actual

2008 2009
Target

Year

Till
Jun
2010

No/Year

10

10

9
7
5

6
3
0
0

0
2005

BenchMark

Aradhana Soft Drinks Company, PANIPAT, INDIA

2006

2007

Actual

2008

Target

2009

Year

Till
Jun
2010

Total no. of Kaizens


1500
1500

1326
1234

1200
974
N o's

900

OPL's

524

600
300
21

1332

1200

0
Actual

Target

Year

Till
Jun
2010

957
Cum. No.

2005 2006 2007 2008 2009

BenchMark

1500
1429

1500

275

900
600

444
258

300
0

0
2005 2006 2007 2008 2009

B e nc hM a rk

Aradhana Soft Drinks Company, PANIPAT, INDIA

A c t ua l

T a rge t

Year

Till
Jun
2010

Quality - GV
Quality - Brix

100

98 98.2799.40 100 99.44

100

100 100

93.0694.8692.22
89 91.38

92.22 95

2005 2006 2007 2008 2009

Till
Jun
2010

75
N o's

N o's

75
50

50
25
25
0
0
2005 2006 2007 2008 2009

BenchMark

Actual

Target

Year

Till
Jun
2010

BenchMark

Actual

Target

Year

Quality TA
100 100

Cum. No.

100

100 99.44

100 100

75
50
25
0
2005 2006 2007 2008 2009

Aradhana Soft Drinks Company, PANIPAT, INDIA

B e nc hM a rk

A c t ua l

T arget

Year

Till
Jun
2010

Water Conserver Award from


UNESCO

TPM LEVEL-1

2009
2008
2007
2006

ZERO EFFLUENT DISCHARGE

AWARDED WITH TPM GOLD KAIZEN AWARD IN


PEPSI INDIA KAIZEN CONFERENCE

CHAIRMAN AWARD RECEIVED FOR REDUCTION IN WATER


CONSUMPTION

Aradhana Soft Drinks Company, PANIPAT, INDIA

2010
ISO 22K
CERTIFIED

ISO 14000

2011- level 2 target

Thanks
Aradhana Soft Drinks Company, PANIPAT, INDIA