Transcript
Page 1: Coca Cola Ashutosh Sachan Training Report

Industrial Training Report

At

Jaipur (Rajasthan)

Submitted to- Submitted by-

Mr. RISHI CHAWLA ASHUTOSH SACHAN

Production Manager Central Institute of Plastics Engineering &

HCCBPL, Jaipur Technology (CIPET), Lucknow

Page 2: Coca Cola Ashutosh Sachan Training Report

CERTIFICATE

This is to certify that ASHUTOSH SACHAN student of B.Tech. (Plastic Engineering)

(2nd

YEAR) [2009-2013] from Central Institute of Plastics Engineering &

Technology, Lucknow has successfully completed his summer training at Hindustan

Coca-Cola Beverages Pvt. Ltd., Jaipur, for a period of four weeks, commenced on 20th

June, 2011.

Mr. RISHI CHAWLA

Production Manager

HCCBPL

Jaipur (Rajasthan)

Page 3: Coca Cola Ashutosh Sachan Training Report

INDEX

Preface

Overview of the Coca-Cola company

The Coca-Cola Company

Coca-Cola System

Hindustan Coca-Cola Beverages Pvt. Ltd., Jaipur

RGB line overview

RGB line flow-chart

RGB line functioning

Curbing Breakage of glass bottles on RGB line

Prime locations of bottles breakage

Immediate actions

Long term plans

PET Bottling Plant Overview

PET Bottling Plant flow-chart

Polyethylene Terephthalate

PET Bottle Processing Equipment

Blow Molding

Extrusion blow molding

Injection blow molding

Stretch blow molding.

Types of Defects in PET Bottles

Basic Equipment Care (BEC)

Total Productive Maintenance (TPM)

Page 4: Coca Cola Ashutosh Sachan Training Report

PREFACE

In-Plant training has been misinterpreted by most of us, Industrial

training, in a true sense, has been included in the curriculum to make the

students well versed with the technical procedure of various industries

and the basic criteria for management of resources in a company or

industry.

The educational institutions sole aim by

industrial training is to improve the technical know-how and to have a

hand on experience to make them realistic in thinking to understanding

the procedure for manufacturing keeping in mind the minute detail

which will benefit the customer. Like no learning is proper without

implementation, similarly the terms and procedures we learn are of no

use until and unless we bring them in practical applications.

To summarize, industrial training

teaches us industrial ethics, advance technical know-how and helps us to

get acquainted with industrial working style.

The document summaries the current

state of Hindustan Coca Cola Beverages Pvt. Ltd., Jaipur, Rajasthan. The

document provides information working procedure and final products of

different divisions. Overall it provides a common wide understanding of

its production procedures & end products.

Page 5: Coca Cola Ashutosh Sachan Training Report

The Coca-Cola Company is a beverage retailer,

manufacturer and marketer of non-alcoholic beverage concentrates

and syrups. The company is best known for its flagship product Coca-

Cola, invented by pharmacist John Stith Pemberton in 1886. The Coca-

Cola formula and brand was bought in 1889 by Asa Candler who

incorporated The Coca-Cola Company in 1892. Besides its namesake

Coca-Cola beverage, Coca-Cola currently offers more than 500 brands in

over 200 countries or territories and serves over 1.6 billion servings

each day.

The company operates a franchised distribution system

dating from 1889 where The Coca-Cola Company only produces syrup

concentrate which is then sold to various bottlers throughout the world the

bottlers hold an exclusive territory contracts with the company, produce

finished product in cans and bottles from the concentrate in combination

with filtered water and sweeteners. The bottlers then sell, distribute and

merchandise Coca-Cola to retail stores and vending machines. Such

bottlers include Coca-Cola Enterprises & Hindustan Coca-Cola Beverages

Pvt. Ltd which is the bottler in India.

The Coca-Cola Company is headquartered

in Atlanta, Georgia. the Coca-Cola company 0ffers 16 brands namely

Coca-Cola, Diet Coke, Thumsup, Sprite, Fanta, Limca, Maaza, Maaza

Milky Delite, Minute Maid Pulpy Orange, MM Nimbu Fresh, Burn,

Kinley Water, Kinley Soda, Nestea, Schweppes & GEORGIA Gold.

Page 6: Coca Cola Ashutosh Sachan Training Report

At the core of business in India, as in the rest of the

world is the production and distribution network, which is called the

“Coca-Cola system”. Globally, the Coca-Cola system includes the

Company and more than 300 bottling partners. The Coca-Cola Company

manufactures and sells concentrate and beverage bases. The authorized

bottlers combine the concentrate or beverage bases as the case may be

with sweetener (depending on the product), water or carbonated water to

produce finished beverages. These finished beverages are packaged in

authorized containers bearing trademarks -- such as cans, refillable glass

bottles, non-refillable PET bottles and tetra packs -- and are then sold to

wholesalers or retailers. In India, additionally, the Company also sells

certain powdered beverage mixes such as Vitingo and Fanta Fun Taste.

The beverages reach ultimate consumers through

customers: the grocers, small retailers, hypermarkets, restaurants,

convenience stores and millions of other businesses that are the final

points of distribution in the Coca-Cola system. What truly defines the

Coca-Cola system, and indeed what makes it unique among businesses, is

the ability to create value for customers and consumers.

In India, the Coca-Cola system comprises of a wholly

owned subsidiary of The Coca-Cola Company namely Coca-Cola India

Pvt. Ltd which manufactures and sells concentrate and beverage bases and

powdered beverage mixes, a Company-owned bottling entity, namely,

Hindustan Coca-Cola Beverages Pvt. Ltd; thirteen authorized bottling

partners of The Coca-Cola Company, who are authorized to prepare,

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package, sell and distribute beverages under certain specified trademarks

of The Coca-Cola

Company and an extensive distribution system comprising of customers,

distributors and retailers. Coca-Cola India Private Limited sells

concentrate and beverage bases to authorized bottlers who are authorized

to use these to produce portfolio of beverages. These authorized bottlers

independently develop local markets and distribute beverages to grocers,

small retailers, supermarkets, restaurants and numerous other businesses.

In turn, these customers make beverages available to consumers across

India.

Page 8: Coca Cola Ashutosh Sachan Training Report

Hindustan Coca-Cola Beverages Pvt. Ltd., Jaipur

Hindustan Coca-Cola Beverages Private Limited at Jaipur was started in late

1999.

To be exact on 26th

December’ 1999, with the production started with the

RGB line, i.e. Return Glass Bottle Line.

PET bottling plant was installed in the year 2003, where the PET bottles were

formed and filled.

Today both the lines are running successfully with an average production of

36000 thousand bottles per hour in RGB Line, i.e. with approximately

capacity of 8,64,000 bottles in a single day. And with 7000-9000 PET bottles

per hour, i.e. approximately capacity of 1,68,000 - 2,16,000 PET bottles

according to different size variants, ranging from 600ml to 2.25 litres

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RGB Line overview

The RGB line deals with the filling of glass bottles of

different shape & volumes. RGB stands for Return Glass Bottle. In

this line empty glass bottles that are brought back from the market are

refilled with fresh beverages. This line has very high production rate

up to 600 BPM (bottles per minute) which results in the production of

36000 bottles per hour which is amongst the highest rate of

production of finished goods in a manufacturing unit.

In this line two key machines that are used is the bottle

filler & crowning machine and the bottles washer. The dirty bottles

are cleaned using the bottles washer that removes all dirt & germs

form the bottles and then the bottles are filled & crowned by the

bottle filler & crowning machine.

This production line is a fully automated line in which

the bottles move on a moving conveyor line, this provides high work

standard & quality to the product.

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RGB line (Return Glass Bottle line) flowchart

1. Input-bottles are

transferred in crates to

conveyor line

2. Bottles are washed by a

water jet

4. Bottles are inspected

manually for irregularities

5. Bottles are washed in a

6-phase bottles washer

6. Bottles are transferred

from bottle washer to filler

conveyor line

7. ASEBI machine separates

defective bottles

8. Beverage is filled in

bottles & crowned by

bottle filler

9. Inkjet printer prints mrp.

and other info on the

bottles

3. Bottles are transferred

from crates to main

conveyor line by encaser

10. Filled bottles are

inspected for defects

manually and separated

11. Filled bottles are

transferred from conveyor

to crates by caser

Flow chart

illustrating

functioning of

RGB line

Empty crates are sent to

crate cleaner for cleaning

Cleaned crates are sent

from crate cleaner to caser

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Functioning of RGB line

1. Bottles to be filled are loaded on the conveyor in crates for filling manually. A

worker transfers the crates one by one to the conveyor from the stack of crates.

2. A water jet cleans the bottles in the crates, this removes some of the dust & other

unwanted materials form the bottles in the crates.

3. The bottles are now transferred from the crates to the conveyor by encase.

The encaser picks up 96 bottles in one go i.e. it picks up bottles from four crates in

one go that is a total of 96 bottles.

4. The bottles are inspected manually for bottles of different brands than the once

that are under production. The unwanted once are removed.

5. The bottles are washed in a 6-phase bottles washer. The bottles washer cleans the

bottles using hot water and a number of chemical cleaning agents.

It mainly uses hot water & caustic for cleaning the bottles. This machine uses

moving pockets for taking the dirty bottles into it for cleaning & putting the

cleaned bottles back to the conveyor.

It has groups of 40 pockets lined together in which the bottles are kept such that

their neck is on the inside of the neck.

The six cleaning steps in a bottles washer are:-

1) Pre rinse by 3 jets.

2) Pre caustic soak 1

3) Pre caustic soak 2

4) Hydro cleaning

5) Pre final rinse treatment 1

6) Pre final rinse treatment 2

6. The cleaned bottles are transferred from the bottles cleaner to the filler

conveyor and are sent for filling to the filler.

7. The EBI machine separates the defective bottles i.e. the bottles with

chipped finish are discarded & the once those are dirty are sent for rewash.

This machine is a credible and precise rotary type inspection machine that

automatically inspects damage, flaw, external substances (bottom and

sidewall of bottle) and uncleanness in an empty bottle. This inspects the

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sidewall of glass containers that camera & illumination is installed to

inspect the inclusions, bubbles, stone, bird wings, laps etc. The machine

performs an inspection without contact between bottle and machine

regardless the production speed. This machine uses a preloaded image that is used as standard, the bottles

passing through the machine are compared to the standard.

8. Beverage is filled in the bottles by the filler and is crowned simultaneously

by the same machine. This machine is a computer controlled machine that

fills pressurized carbonated drink in the bottles. The vent first sends carbon

dioxide inside the bottle that in turn develops a counter pressure that

opens a valve which enables inlet of beverage in the bottle. As soon as the

bottles are filled the filled bottles are transferred to the crowning section

where the crowns are fitted on the heads of the bottles which seals them.

9. The inkjet printer prints data as required on the filled bottles. The printer

generally prints maximum retail price, batch number of production,

production date & time on the bottle.

The data to be printed on the bottles is set by a computer system in the

machine comprising of a display & keyboard. The data to be printed is set

using this system.

10. The filled bottles are inspected manually for leaked bottles, bottles that

are not filled properly & bottles that are not crowned properly.

The bottles that are found defective are removed and are sent for refilling.

11. The filled bottles are transferred from the conveyor line to the crates by

caser.

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Curbing Breakage of glass bottles on RGB line

Prime locations of bottles breakage

1. At the place where the worker loads the crates on the conveyor.

2. At the EBI where bottles with chipped finish are discarded

3. At the crate cleaner

4. At the filling machine

5. Along the conveyor belt ( bottles fall due to slipping off the conveyor)

6. At the location where crowned bottles are inspected for defects.

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Immediate actions

Placing bins of proper shape for bottle collection instead of drums used

presently at specified locations.

Bins of such shape will enable proper collection of the bottles and easy

replacement when filled. The bins should have wheels that would make

them easily movable when they are filled helping the workers to

remove them easily form time to time.

Locations for use of such bins:- EBI machine, crate cleaner &

inspection site of crowned bottled.

The size of the guard rails on the conveyor could be increased on the

turn, this will reduce the slipping of bottles on the turns because

generally many bottles fall on the turns which result in bottles breakage.

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Long term plans

At the loading site where worker puts the crates on the conveyor

A conveyor could be installed below the main conveyor that moves opposite

in direction to the main conveyor, it would carry the bottles to a specified

point where the bottles could be collected and removed periodically. This is

the only possible measure at this location because there is no room for

placing a bin for collection of bottles.

The above sketch shows the side view of the conveyor that could be installed

below the main crate carrying conveyor this conveyor would carry the bottles

falling from the crates.

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The sketch below shows the front view of the conveyor that could be

installed below the main crate carrying conveyor, metal sheets or metallic

mesh could be installed as side guards which would guide the bottles falling

into the moving conveyor below the main conveyor.

At the EBI where bottles with chipped finish are discarded

A conveyor could be set here also carry the bottles to a specified point where

the bottles could be collected and removed periodically.

Or

AGC (automatic guided carts) could be used to collect, carry & dump the

bottles at a predefined site.

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AGC (automatic guided carts) are smart carts that move on pre specified

path marked by magnetic tape. Set of two AGCs could be deployed at every

site to collect and dump the broken glass bottles.

System for removal of glass spilled on the floor

Commercial vacuum cleaner can be deployed for removal of glass pieces on

the floor. A high suction vacuum cleaner can lift small and larger pieces of

glass. This could be operated by just a single person at certain time intervals

in the production area especially inside the filling room to remove glass

pieces from the floor.

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PET Bottling Plant Overview

1. The packaged preform or parison are fed to the hopper, through which they are fed to the stretch

blow molding machine.

2. The preforms in the stretch blow molding machine are provided a rotary motion and are

sufficiently heated above the glass transition temperature of PET i.e. 76 degrees, with the help

of heaters of wattage 1600W and 1200W and then are fed to the two piece mould for blow

molding, where they are first stretched longitudinally with the help of a stretching rod, and then

pre final pressured air (14-16 bar) is blown followed by a final pressure of 34-36 bar.

3. The pet bottle takes the shape of the mould and is cooled down inside the mould itself. A

continuous flow of cold water takes place inside the mould for cooling of the PET bottles.

4. Formed PET bottles are transferred through air conveyers through blowers

5. The bottles are then fed to the filling area where they are first washed with water at a pressure of

2 kilograms

6. Then in the filling area, a pressure of five kilograms is applied, to check any leakage or

deformation in the bottle. If any bottle detected with leakage the beverage is not filled inside

and is rejected.

7. After application of pressure, carbonated beverage is then filled inside the PET bottles and then

capping of bottles takes place.

8. After capping the bottles are fed through conveyor to the warmer for warming the bottles, so as

to remove the condensed water vapors from the bottle surface. Warm water at a temperature of

40 degrees is used.

9. After warming up the filled bottles the send for labeling, where the labels of the particular

variant is made to stick on the beverage bottles.

10. After labeling, coding is done. Batch number, date and time are printed on the bottles.

Then the bottles are fed to the caser machine where they are packed in cartons, followed by upper

tapping of the cartons, and then the cartons are manually lifted and stacked.

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Preforms or Parison

Rotary Motion

Heating of Preform

Stretch Blow Molding

PET Bottle

Air Conveyor Filling Area

Washing at 2kg water

pressure.

5kg Air pressure

Capping (Sealing)

Transfer to warmer

Labeling

&

Coding

Caser Machine

&

Carton packaging.

Flow Chart: Plant Overview

Page 20: Coca Cola Ashutosh Sachan Training Report

Polyethylene Terephthalate

(PET)

Polyethylene terephthalate (sometimes written poly(ethylene terephthalate)), commonly abbreviated

PET, PETE, or the obsolete PETP or PET-P, is a thermoplastic polymer resin of the polyester family

made by condensing ethylene glycol and terephthalic acid, and is used in synthetic fibers; beverage,

food and other liquid containers; thermoforming applications; and engineering resins often in

combination with glass fiber.

Polyethylene Terephthalate

PET is a semi-crystalline thermoplastic, which softens at approx. 76°C (what is called “Glass

Transition”). Above this temperature, the material becomes elastic, and can be formed, a property

utilized effectively in the Stretch Blow Molding process.

Due to its glass transition at approx. 76°C, PET is initially unsuitable as a bottle material for a hot-

filling process above this temperature, since deformations may occur: Firstly, the bottles shrink, since

they “remember” their previous shape (namely the preform), and secondly they collapse under internal

pressure, a typical phenomenon during the cool-down period after hot filling.

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PET Bottle processing equipment

There are two basic molding methods for PET bottles, one-step and two-step.

In two-step molding, two separate machines are used. The first machine injection molds the

preform, which resembles a test tube, with the bottle-cap threads already molded into place. The

body of the tube is significantly thicker, as it will be inflated into its final shape in the second

step using stretch blow molding.

In the second step, the preforms are heated rapidly and then inflated against a two-part mold to

form them into the final shape of the bottle.

In one-step machines, the entire process from raw material to finished container is conducted

within one machine, making it especially suitable for molding non-standard shapes (custom

molding), including jars, flat oval, flask shapes etc. Its greatest merit is the reduction in space,

product handling and energy, and far higher visual quality than can be achieved by the two-step

system.

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Blow Molding

Blow molding (also known as blow molding or blow forming) is a manufacturing process by which

hollow plastic parts are formed.

In general, there are three main types of blow molding:

Extrusion blow molding,

Injection blow molding, and

Stretch blow molding.

The blow molding process begins with melting down the plastic and forming it into a parison or

preform. The parison is a tube-like piece of plastic with a hole in one end in which compressed air

can pass through.

The parison or preform is then clamped into a mold and air is pumped into it. The air pressure then

pushes the plastic out to match the mold. Once the plastic has cooled and hardened the mold opens up

and the part is ejected.

Page 23: Coca Cola Ashutosh Sachan Training Report

Extrusion blow molding

In extrusion blow molding (EBM), plastic is melted and extruded into a hollow tube (a

preform). This preform is then captured by closing it into a cooled metal mold. Air is then blown into

the preform, inflating it into the shape of the hollow bottle, container or part. After the plastic has

cooled sufficiently, the mold is opened and the part is ejected. Continuous and Intermittent are two

variations of Extrusion Blow Molding.

In Continuous Extrusion Blow Molding the preform is extruded continuously and the individual parts

are cut off by a suitable knife.

In Intermittent blow molding there are two processes: straight intermittent is similar to injection

molding whereby the screw turns, then stops and pushes the melt out. With the accumulator method, an

accumulator gathers melted plastic and when the previous mold has cooled and enough plastic has

accumulated, a rod pushes the melted plastic and forms the preform. In this case the screw may turn

continuously or intermittently.

EBM processes may be either continuous (constant extrusion of the preform) or intermittent.

Extrusion blow molding

1. Reciprocating screw 6. Heaters

2. Compressed air; 7. Grinding, mixing

3. Hopper; 8. Actuator’s hydraulic generator

4. Granules; 9. Draw plate

5. Barrel; 10. Core/punch

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Injection blow molding

The process of injection blow molding (IBM) is used for the production of hollow glass and

plastic objects in large quantities. In the IBM process, the polymer is injection molded onto a core pin;

then the core pin is rotated to a blow molding station to be inflated and cooled. This is the least-used of

the three blow molding processes, and is typically used to make small medical and single serve bottles.

The process is divided into three steps: injection, blowing and ejection.

The injection blow molding machine is based on an extruder barrel and screw assembly which melts

the polymer. The molten polymer is fed into a manifold where it is injected through nozzles into a

hollow, heated preform mold. The preform mold forms the external shape and is clamped around a

mandrel (the core rod) which forms the internal shape of the preform. The preform consists of a fully

formed bottle/jar neck with a thick tube of polymer attached, which will form the body.

The preform mold opens and the core rod is rotated and clamped into the hollow, chilled blow mold.

The core rod opens and allows compressed air into the preform, which inflates it to the finished article

shape.

After a cooling period the blow mold opens and the core rod is rotated to the ejection position. The

finished article is stripped off the core rod and leak-tested prior to packing. The preform and blow mold

can have many cavities, typically three to sixteen depending on the article size and the required output.

There are three sets of core rods, which allow concurrent preform injection, blow molding and ejection.

Injection Blow Molding Machine

Page 25: Coca Cola Ashutosh Sachan Training Report

Stretch Blow Molding

In the stretch blow molding (SBM) process, the plastic is first molded into a "preform" using

the injection molding process. These preforms are produced with the necks of the bottles, including

threads (the "finish") on one end. These preforms are packaged, and fed later (after cooling) into a

reheat stretch blow molding machine. In the SBM process, the preforms are heated (typically using

infrared heaters) above their glass transition temperature, then blown using high pressure air into

bottles using metal blow molds. Usually the preform is stretched with a core rod as part of the process.

In the single-stage process both preform manufacture and bottle blowing are performed in the same

machine. The stretching of some polymers, such as PET (polyethylene terephthalate) results in strain

hardening of the resin, allowing the bottles to resist deforming under the pressures formed by

carbonated beverages. The main applications are bottles, jars and other containers.

Advantages of blow molding include: low tool and die cost; fast production rates; ability to mold

complex part; produces recyclable parts

Disadvantages of blow molding include: limited to hollow parts, wall thickness is hard to control.

Stretch Blow Molding Process

Page 26: Coca Cola Ashutosh Sachan Training Report

Types of Defects in PET Bottles

Deformed neck

Folded neck

Base Clearance on a Champagne Base Bottle

Choked Bottle

Excess material on the base

Flat on the parting line

Magnification effect

Magnification effect on base

Off centered injection point

Opalescence

Pearlscence

Punctured base

White feet

White feet / injection point off centered

White feet / over stretched base

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DEFORMED NECK

Causes:

Excessive temperation in the zone under the neck

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FOLDED NECK

Causes:

Wrong profile in the oven

Late pre-blowing

Pre-blowing pressure too low

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BASE CLEARANCE ON A

CHAMPAGNE BASE BOTTLE

Causes:

Mold temperature excessively hot

Excessive heat and temperature in base zones

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CHOKED BOTTLE

Causes:

Low temperature in the oven

Delay in the pre-blow

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EXCESS MATERIAL

ON THE BASE

Causes:

Low temperature in Zones 7 & 8

Delay in pre-blowing

Pre-blow pressure low

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OFF-CENTERED

INJUCTION POINT

Causes:

High temperature in Zones 7 & 8

Pre-blowing too soon

Pre-blow pressure too high

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FLAT ON THE PARTING LINE

Causes:

The pre-blow is either too low or too late

High-blow is premature or too high

Mold compensation not properly adjusted

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OPALESCENCE

Causes:

Blowing with high temperature

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PEARLESCENCE

Causes:

Blowing with cold temperature

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Magnification Effect

Causes:

Low temperature in Zone 1 & 2

High pressure in the pre-blowing process

Pre-blowing too early

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White Feet

Causes:

Low temperature in the oven

Low temperature in Zones 7 & 8

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White Feet/Over-Stretched Base

Causes:

High temperature in the oven

High temperature in Zones 7 & 8

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Punctured Base

Causes:

Excessive temperature in Zone 8

Pre-blow pressure too high

Pre-blowing much too early

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White Feet/Injection

Point Off Centered

Causes:

Low temperature in the oven

(Specially Zones 7 & 8)

Early pre-blowing

Pre-blowing pressure slightly high

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Magnification Effect on

The Base

Causes:

Low temperature in Zone 7 & 8

Too great of a delay in pre-blowing

Pre-blowing pressure too low

Page 42: Coca Cola Ashutosh Sachan Training Report

Basic Testing of PET Bottles

Hot Wire Bottle Cutter

PET bottle test sample of capacities 500ml to 2.25 lts can be precisely cut in 3 parts:

bottom, cylinder and top. Each of these parts having exact assigned weights, to comply

with the quality specification obtaining an ideal wall thinness distribution. This

guarantees the physical and mechanical quality requirement. The product process is

being controlled on a statistical basis by checking the weight of the cut parts.

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Basic Equipment Care

(BEC)

Basic Equipment Care deals with mainly caring, oiling and greasing of parts

like bearings, rollers, pulleys, wheels, timely tightening of nut-bolts and

various other machinery parts and timely maintenance of machines.

Step zero- Safety

One needs to physically inspect his surroundings for immediate

safety measures.

Step One- Initial cleaning

Cleaning to Inspect

Inspect to Detect

Detect to Correct

Types of Abnormalities:-

Minor Flow

Poor Basic Condition

Inaccessible place

Contamination source

Quality item

Unsafe area

Page 44: Coca Cola Ashutosh Sachan Training Report

Total Productive Maintenance

(TPM)

Total productive maintenance (TPM) originated in Japan in 1971. It

may be misunderstood as a new way of looking at maintenance, however, at

least in Japan, it is a well-established process.

In TPM, the machine operator is thoroughly trained to perform much of

the simple maintenance and fault-finding. Eventually, by working in "Zero

Defects" teams that include a technical expert as well as operators, they can

learn many more tasks - sometimes all those within the scope of an operator.

Tradesmen are also trained at doing the more skilled tasks to help ensure

process reliability.

This should be fully documented, Autonomous Maintenance ensures

appropriate and effective efforts are expended after the machine becomes

wholly the domain of one person or team. Safety is paramount, so training

must be appropriate. Operators are often capable of high standards of

technical ability, this is improved through the use of "best practice"

procedures and proper training of these procedures.

TPM is a maintenance process developed for improving productivity by

making processes more reliable and less wasteful. Original goal of total

productive management:

“Continuously improve all operational conditions, within a production

system; by stimulating the daily awareness of all employees”

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TPM focuses primarily on manufacturing (although its benefits are

applicable to virtually any "process"). After TPM, the focus was stretched,

and also suppliers and customers were involved (Supply Chain), this next

methodology was called lean manufacturing. This sheet gives an overview of

TPM in its original form.

An accurate and practical implementation of TPM, will increase productivity

within the total organization, where:

(1) .. a clear business culture is designed to continuously improve the

efficiency of the total production system

(2) .. a standardized and systematic approach is used, where all losses are

prevented and/or known.

(3) .. all departments, influencing productivity, will be involved to move from

a reactive- to a predictive mindset.

(4) .. a transparent multidisciplinary organization is reaching zero losses.

(5) .. steps are taken as a journey, not as a quick menu.

Finally TPM will provide practical and transparent ingredients to reach

operational excellence.


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