Reduction of Changeover Time in a Bottling Plant

Dept Of IEM, DSCE Page i

TABLE OF CONTENTS
Page Number
ABSTRACT i
TABLE OF CONTENTS ii
LIST OF TABLES vi
LIST OF FIGURES vii

CHAPTER 1
INTRODUCTION 1-9
1.1 Down Time 2
1.2 Down Time Reduction .... 2
1.3 The down time reduction approach 3
1.4 Issues in a bottling plant 4
1.5 Need of reducing Down time 6
1.6 Five ways to reduce the Down Time 7

CHAPTER 2
LITERATURE SURVEY 10-13

CHAPTER 3
COMPANY PROFILE 15-16
3.1 Introduction to Coca-Cola 15
3.2 About Hindustan Coca-Cola Beverages Pvt.Ltd 16


Reduction of Changeover Time in a Bottling Plant

Dept Of IEM, DSCE Page ii

CHAPTER 4
PROBLEM IDENTIFICATION 17-19
4.1 Introduction to Problem Identification 18
4.2 Problem Identified 18
4.3 Expected Outcomes after Improvement 19

CHAPTER 5
METHODOLOGY & TOOLS 20-29
5.1 Lean Manufacturing 21
5.1.1 Introduction To Lean Manufacturing 21
5.1.2 Principles of Lean 21
5.1.3 Lean Tools 22
5.1.4 Lean Implementation Plan: Importance and Development 23
5.1.5 Characteristics Of Lean Manufacturing 23
5.1.6 Benefits of Lean Manufacturing 24
5.2 Time Studies 24
5.2.1 Two Handed Process Chart 25
5.3 Value Stream Mapping 26
5.3.1Value Stream Mapping as an Essential Tool 28
5.3.2 Value Symbols Used 29

CHAPTER 6
DATA COLLECTION 31-39
6.1 Understanding The Process 32
6.2 Definitions And Terminologies 39

Reduction of Changeover Time in a Bottling Plant

Dept Of IEM, DSCE Page iii

CHAPTER 7
VALUE STREAM MAPPING 40-47
7.1 Methodology 41
7.2 Steps Involved In Creating Current State Map 41
7.3 Current State Mapping 42
7.4 Calculation Of Maintanence Efficiency 46

CHAPTER 8
IMPLEMENTATION
8.5 Brain Storming 47
7.6 Implementation Plan 47
7.6.1 Implementation Plans Proposed
REFERENCES 51
APPENDICES 57













Reduction of Changeover Time in a Bottling Plant

Dept Of IEM, DSCE Page iv

LIST OF TABLES
Table
number
Title Page number
6.1 Benchmark times for various Changeovers 33
6.2 Changeover data (February 2014) 34
6.3 Changeover data (March 2014) 35
6.4 Changeover data (April 2014) 37
6.5 Two handed Process Chart Results 38
7.1 Summary of Non-value adding Activities 43
7.2 Summary of MTTO Activities 44
7.3 At the blower station: pre-CO activities 44


















Reduction of Changeover Time in a Bottling Plant

Dept Of IEM, DSCE Page v

LIST OF FIGURES
Figure
number
Title Page number
1.1 Conveyors of a bottling plant for returnables 4
2.1 Delineation of MMLT 12
3.1 Coca-Cola system 15
5.1 Lean Implementation Cycle 22
5.2 Example of two-handed process chart 26
5.3 Value Stream Map arranged in cyclic form 27
5.4 VSM Symbols 30
3.3 Simulation Model for PID Control of Roll
Angle
21
3.4 Simulation Model of Servomotor Control 22
3.5 Schematic of Observer in the system 24
3.6 Target marker for landing 26
3.7 HSV colour space 27
3.8 Displacement nodal solution 29
3.9 Stress distribution 31
3.10 Polyester resin and catalyst 32
3.11 Application of resin on the ceramic plate 35
3.12 Laying of Fiber Glass cloth over resin layer 36
3.13 Application of resin over fiber glass 37
3.14 Complete quadcopter structure 37
3.15 Docking station concept 1 38
3.16 Docking station concept 2 39
3.17 Docking station concept 3 39
3.18 Docking station concept 4 40
3.19 Docking station concept 5 41
3.20 H-Bridge circuit 42
3.21 L298 IC 42
3.22 74HC4052 Mux 42
3.23 Lead Acid Battery 43
3.24 Lead Acid Battery Charger Circuit 43
4.1 Roll stabilization performance 45
4.2 Pitch stabilization performance 46
4.3 Yaw stabilization performance 48
4.4 Pitch Axis Response (Desired Angle vs
Time)
49
4.5 Yaw Axis Response (Desired Angle vs
Time)
53
4.6 Waypoint Navigation X co-ordinate 55
4.7 Waypoint Navigation Y co-ordinate 56
4.8 Auto Landing of Quadcopter 56
4.9 Docking Station 57