Académique Documents
Professionnel Documents
Culture Documents
PEPSICO
Pepsico World wide
PepsiCo India
30% Growth in FY 09
Our Brands
Site Information
PLANT ESTABLISHED IN 1991
ACQUIRED BY PI IN 2003
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
Manufacturing Process
Blow Moulding M/cs
Filler
MIX Processor
Taping M/cs
Warmer
Sleever
Labeller
Story of Transformation
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
Master Plan
Autonomous Maintenance
Approach
Forming of Team
Identification Model
M/CS
Making of Kaizens
& OPLS
General Inspection
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
Making of Kaizens
& OPLS
General Inspection
BEFORE
AFTER
Step 1
Forming of Team
Identification Model
M/CS
Lubrication Map of
Popular Circle
Heating
Tunnel
Collecting
Table
Buffer
Conveyor
Sleever
Cooling
Tunnel
Making of Kaizens
& OPLS
General Inspection
Before
Aradhana Soft Drinks Company, PANIPAT, INDIA
Before
After
After
Before
After
Step1
Forming of Team
Identification Model
M/CS
Making of Kaizens
& OPLS
General Inspection
Step-2
Process Flow Chart
Forming of Team
Identification Model
M/CS
Making of Kaizens
& OPLS
General Inspection
BEFORE
Aradhana Soft Drinks Company, PANIPAT, INDIA
AFTER
Step-2
Process Flow Chart
Forming of Team
Identification Model
M/CS
Making of Kaizens
& OPLS
General Inspection
Step-2
Process Flow Chart
Forming of Team
Identification Model
M/CS
Making of Kaizens
& OPLS
General Inspection
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
Making of Kaizens
& OPLS
General Inspection
Pg No.46
VISUAL CONTROLS
For ease of Inspection and early detection
For checking abnormalities in critical process parameters.
Step-4
PREPARATION
TRAINING AIDS
Forming of Team
Working
Model
Identification Model
M/CS
Cutsections
OPL
Forming & Performing
of CLITA & Tagging
TRAINING
Training
Manuals
OJT
General
Fastner
4
Mc. Condition
Making of Kaizens
& OPLS
safety
Actual
Drive
Training Model
Lubrication
AUDIT
Pneumatics
Electrical
BM
Target
General Inspection
3
2
1
0
GENERAL
Inspection
INSPECTION
Sheets
Hydraulics
OEM Training
BEFORE
AFTER
BEFORE
AFTER
BEFORE
AFTER
BEFORE
AFTER
BEFORE
AFTER
BEFORE
AFTER
BEFORE
AFTER
BEFORE
AFTER
BEFORE
Aradhana Soft Drinks Company, PANIPAT, INDIA
AFTER
BEFORE
Aradhana Soft Drinks Company, PANIPAT, INDIA
AFTER
BEFORE
Aradhana Soft Drinks Company, PANIPAT, INDIA
AFTER
BEFORE
Aradhana Soft Drinks Company, PANIPAT, INDIA
AFTER
BEFORE
Aradhana Soft Drinks Company, PANIPAT, INDIA
AFTER
BEFORE
Aradhana Soft Drinks Company, PANIPAT, INDIA
AFTER
BEFORE
Aradhana Soft Drinks Company, PANIPAT, INDIA
AFTER
BEFORE
Aradhana Soft Drinks Company, PANIPAT, INDIA
AFTER
BEFORE
Aradhana Soft Drinks Company, PANIPAT, INDIA
AFTER
BEFORE
Aradhana Soft Drinks Company, PANIPAT, INDIA
AFTER
BEFORE
Aradhana Soft Drinks Company, PANIPAT, INDIA
AFTER
8.40
8
8
5.47
6
6.86
6.11
7
5.53
6.05
%
4
3
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
A c t ual
T a rge t
Year
Till
Jun
2010
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
2006
2007
Actual
2008
Target
2009
Year
Till
Jun
2010
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.
BenchMark
1500
1429
1500
275
900
600
444
258
300
0
0
2005 2006 2007 2008 2009
B e nc hM a rk
A c t ua l
T a rge t
Year
Till
Jun
2010
Quality - GV
Quality - Brix
100
100
100 100
93.0694.8692.22
89 91.38
92.22 95
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
B e nc hM a rk
A c t ua l
T arget
Year
Till
Jun
2010
TPM LEVEL-1
2009
2008
2007
2006
2010
ISO 22K
CERTIFIED
ISO 14000
Thanks
Aradhana Soft Drinks Company, PANIPAT, INDIA