IMPROVING OPERATIONAL EFFICIENCY

AT HECTOR BEVERAGES PVT LTD

A Summer Internship Project by S Prashant Reddy

INDEX

• Company Profile

• Assembly Line

• Problem Statement

• Data Collection Method

• Data Analysis

• Findings

• Suggestions

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.

CORE VALUES & QUALITY POLICYCore 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.”

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.

• Lemon Mint

• Tropical Trip

• Apple

• Mango

• Mango Strawberry

PRODUCTS

Energy Drink - TZINGA

• Aamras

• Aam Panna

• Jaljeera

• Imli Ka Amlana

• Jamun Kala Khatta

• Kokum

• Golgappe Ka Pani

Fruit Juices - PAPERBOAT

PRODUCTS

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

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.

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.

DATA ANALYSIS

• In the first stage data was collected about defectives that occur in filler station during the packaging of the beverage.

• The defectives were as followsDate 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.

• 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  

Date Coding76%

Empty Pouch5%

Low Fill4%

Cap Fitting15%

Burst0.32%

Defects after Packaging

Date Coding Empty Pouch Low Fill Cap Fitting Burst

• 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

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 %  

Alignment51%

Printing16%

Visibility5%

No Date Coding28%

Date Coding Defects

Alignment Printing Visibility No Date Coding

• 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.

Spouting of the pouches not done properly.M

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Na

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Ma

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Ma

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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

Me

th

od

Alignment of the sensor being disturbed

FISHBONE DIAGRAM FOR MISALIGNEMENT OF DATE CODING DEFECT

Pouches inserted in the opposite directionM

en

Mo

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Na

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Ma

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in

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Ma

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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

Method

Alignment of the Sensor Being Disturbed

FISHBONE DIAGRAM FOR MISSING OF DATE CODING DEFECT

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.

• 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 toLack 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.

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.

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

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.