hindustan coca cola
DESCRIPTION
hccTRANSCRIPT
-
Classified - Internal use
Khurda, Odisha
-
Achieve Safety Excellence through Behaviour Change
Outline of Company
Global Vision & Mission
-
Internal Use Only Classified - Internal use
About Us
HCCB is organized into 7 operating Zones split by Geography
HCCBPL, Khurdha
25 Bottling Units for manufacturing & Distribution in India.
Operation is divided in to 7 Zones.
Corporate Office Located in Gurgaon.
Total No of Employees 9247
Total Business operation in Revenue 8000 Cr
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Product Portfolio
RGB CSD (200 & 300 ml) :- Fanta, Coke, ThumsUp, Sprite
RGB Maaza (200 & 250 ml) : Maaza
PET CSD (600,1250,2000, 2250 ml) : Kinley Soda, Thums Up, Sprite,Coke,Fanta
Retail Water (1000 ml) : Kinley Water
Tetra Pak (200ml) : Maaza
Plant Capacity
RGB CSD : 600 BPM
RGB Maaza : 600 BPM
PET CSD : 140 BPM
Retail Water : 75 BPM
PET CSD Krones : 600 BPM
Tetra Pak : 400 PPM
Plot size : 38 acres 6 Lines
Tetra Pak
RGB Maaza
PET CSD 140
PET Krones 600 BPM
RGB CSD
KINLEY water
Abbreviation RGB : Retainable Glass Bottles CSD : Carbonated Soft Drink PET : Polyethylene Terephthalate
Factory Overview
Our Product Range
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Plant History
9.58 11.09
15.09 16.10
0
5
10
15
20
2010 2011 2012 2013
Cases i
n M
M
Year
Production Volume
Production
Khurda Unit is a part of Combined East Zone
in HCCBPL.
Located at Khurda District, near Bhubaneswar,
Capital city of Odisha, an area of 38 acres.
Its Green filed Project started its Operation in the
year 1999
68% Growth
-
Achieve Safety Excellence through Behaviour Change
Policies & Objectives
In fulfilling this responsibility, we are committed to -
1. Establish the Cluster/Area Safety Councils and Factory Safety Councils under the leadership and
supervision of the Apex Safety Council at Corporate and regularly review our OSH Policy, objectives &
metrics for effective implementation & continual improvement of Safety Management System.
2. Establish and maintain programs to ensure compliance with more stringent of legal requirements and
those of TCCC requirements relating to OSH.
3. Ensure the provision of resources necessary to achieve our OSH objectives; and foster continual
improvement in OSH performance.
4. Proactively seek to identify, assess and control OSH risks related to our operations.
5. Provide clearly defined roles and responsibilities, training, communication systems and participation
opportunities to promote effective engagement by Associates at each level.
6. Manage OSH incidents in a manner that protects our Associates, assets, business partners and the
public, as well as the image and trademarks of TCCC, consistent with applicable legal requirements.
7. Integrate OSH in business plans, results, performance reviews and other business routines. We, at Hindustan Coca-Cola Beverages Private Limited hereby adopt our OSH Policy, which shall be made available to all Associates. The Apex Safety Council is hereby entrusted with the responsibility of implementing our OSH Policy using our Safety Principles. T. Krishna kumar
We at Hindustan Coca-Cola Beverages Private Limited (Company) believe that our people are our most
valuable asset. Providing a safe and healthy working environment is one of our primary responsibilities and
is fundamental to our success. This belief is part of our culture, and the Occupational Safety and Health
(OSH) Policy applies across all our operations.
We endeavour to conduct our business with the goal of zero work-related injuries for our Associates and
business partners present at our workplace. We will strive to improve workplace safety and health by
engaging with our Associates and adhering to applicable requirements of the law and The Coca-Cola
Company, Atlanta, USA (TCCC) relating to OSH. We also believe that it is the responsibility of each
Associate to ensure compliance with the OSH Policy and programs.
-
Occupational Safety & Health Policy
-
In fulfilling this responsibility, we are committed to 1. Establish the Zone/Area Safety Councils and Factory Safety Councils under the leadership and
supervision of the Apex Safety Council at Corporate and regularly review our OSH Policy, objectives & metrics for effective implementation & continual improvement of Safety Management System.
2. Establish and maintain programs to ensure compliance with more stringent of legal requirements and those of TCCC requirements relating to OSH.
3. Ensure the provision of resources necessary to achieve our OSH objectives; and foster continual improvement in OSH performance.
4. Proactively seek to identify, assess and control OSH risks related to our operations.
5. Provide clearly defined roles and responsibilities, training, communication systems and participation opportunities to promote effective engagement by Associates at each level.
6. Manage OSH incidents in a manner that protects our Associates, assets, business partners and the public, as well as the image and trademarks of TCCC, consistent with applicable legal requirements.
7. Integrate OSH in business plans, results, performance reviews and other business routines.
Leadership Commitment on safety principle:
-
Road Safety Guidelines
-
1. Job specific safety induction at gate - for All (TVs have been provided to brief hazards and protection of people). Strong Gate ACCESS Control. 2. Marshaling of Truck and Forklift inside plant and depots. Better supervision of Shipping Operations (70% of temporary labor is in shipping operations where maximum FLT & Truck movements happen) 3. Mandatory Conformance to safe Permit to Work (PTW). All hot work, confined space, HT electrical, Roof work etc. comes as part of PTW. 4. Mandatory Safety Clause Insertion in all Contract Agreements. This insures responsibility of 'labor' at HCCBPL site - in hands of contractors 5. Mandatory Defensive Driving Training for all Associates, Drivers, FLT drivers, 2W & 4W users. Mandatory use of Helmets for 2 W and Seatbelts in 4W 6. Mandatory use of Machine Interlocks - and no bypassing of the same 7. Mandatory Use of PPE - Safety Shoes for all, cut-resistant gloves & goggles for Glass handling and Helmets for working above 8 FT (especially on top of trucks) 8. Weekly 'Leadership Safety Walks' at Plants and Depots and not to walk past an Unsafe Act.
Mandatory Safety Norms Cardinal Rules
-
We at Hindustan Coca-Cola Beverages Pvt. Ltd, Khurda produce and deliver our
products and provide services with a goal of zero work related injuries and illnesses
for our employees, contractors and all others who came to our plant. Occupational
Health and Safety is one of our highest priorities and we believe that people are our
most valuable asset. We take our responsibility for providing a safe and healthy
working environment and minimizing risks to employees, contractors, and others
seriously. Fulfilling its responsibility is fundamental to the success of our business.
Occupational Health Policy
-
Environment Management Policy
We, at HCCBPL, Khurda ensure a healthy and sustainable environment while protecting and preserving the
environment and reducing environmental footprints through effective implementation of Environment Management
System complying to all applicable statutory and regulatory requirements with active engagement of all the
employees.
TOWARDS THIS POLICY, WE SHALL ENDEAVOR TO ADOPT THE FOLLOWING STRATERGIES
1. Conservation of natural resources specifically in water by continually improving its usage and reducing wastage.
2. We ensure the minimal emission of carbon to the environment.
3. We shall maintain sustainable packaging through recycling of PET bottles.
4. We formulate environmental objectives and targets and integrate a continuous process reviewing all essential elements.
5. We ensure proper infrastructure and resources for continual improvement in environmental performances.
6. The company maintains its commitment to follow and comply all applicable statutory, regulatory and TCCC requirements.
7. Identifying and evaluating all possible environmental risks and taking corrective actions to mitigate those risks and ensuring compliance with TCCC
and applicable legal requirements.
8. We prepare for potential emergencies mitigation programs to protect our associates,contractors,customers and public and prevent property losses
and business interruptions.
9. We strive to consistently improve the capability of our workforce to perform their jobs effectively by providing proper training and awareness and
effective communication system and a dedicated core team with defined roles and responsibilities ensures effective implementation of Environment
Management System.
10. The company ensures to take stewardship initiatives with public and private entities with collaboration to governments, on-governmental organizations
and others through corporate social responsibility programs to improve environmental aspects of the community.
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Achieve Safety Excellence through Behaviour Change
2010:
Low- Safety
awareness /
culture and
safety Infra
2011:
Initial
Transformation
phase- Acceptance
of safety aspects
and initiatives
2012:
Recognize safety as
a part of daily
operation
/ job, building Safety
awareness / culture
2013:
Ownership culture
development and
Audit by safety
personnel
Journey of Safety Excellence
Raising Mass Awareness through
engagement / Campaign / training
Implementing Safety Best Practices
( Elements of TSI- Leading Indicator)
Safety Hardware /Infra correction /
Audits
Safety own by the process owner with
TPM
Our Journey of safety excellence towards the objective with at least
one focus point on year by year
-
Achieve Safety Excellence through Behaviour Change
Apex Safety Committee- At Corporate (Comprising of CEO, Sr. VP- Operations, Sr. VP- Supply Chain, Sr. VP- HR, AVP-Safety VP-
Supply chain, VP-RTM)
Zonal Safety Committee (ZVP/ZSCM of the zone along with respective Factory Managers, RTM Head(s) or Unit,
Zone, zonal Safety manager, zonal Distribution Manager, Zonal HR Head,)
Safety Circles (Team Leaders,
Executives, Operators & Technicians)
Factory Safety Committee
(Factory Manager, Factory Shipping Manager, Factory Production Manager, Factory Quality
Manager, Factory Safety Executive/manager Factory Maintenance Manager, Operators)
Policies Deployment & Review System
CMC (Regular Contractor,
Engineering
Contractor, Project)
DMC Transport Drivers
-
Achieve Safety Excellence through Behaviour Change
Objectives and Performance
(Water Neutrality)
-
Achieve Safety Excellence through Behaviour Change
Cultural
Leadership Walk-Safety Gemba Tours by Leaders
Frontline Participation-Plant Safety Meeting and Tool Box talks
Contractor Safety Management
Proactive Incident Management
Management
Critical Safety Project Establishment
HIRA & Operational Control of Critical Equipment
EHS Software usage for Data Reporting
RED BOOK Compliance
Cardinal rule Compliance
Environment Assurance process
Element of Total Safety Index (TSI)-2013
41.0 51.0 62.5 65.0 66.0 67.0 71.0
75.0 83.0 84.0 88.0 83.0
60 70
80
0.0
20.0
40.0
60.0
80.0
100.0
Actual
New Parameter added
Jan `2013
4.5 6.0 7.5 7.5 7.5 7.3 7.5 7.5 9.3
9.3 9.5 9.0
3.8 4.5
5.4 5.8 6.0
6.3 6.8 7.5 7.7 7.8 8.3 7.8
Culture Management System
-
Gemba Walk
Lead by Factory Manager
Schedule at Thursday of every
week
All HODs mandatory to
participate
Minimum 5 Person must be present
Tracking of Attendance
Tracking of Findings and Mitigation
Every week Compliance present
in weekly review
Leadership Gemba Walk
-
Dec-13 Width Depth
Department Owner Area No of Topic
No of person covered
QA B B Panda 10 29.00%
Production
T R Seshu
Tetra 8 43.00%
RGB 9 34.00%
PET-140 10 100.00%
B.warlu
Kinley 10 68.00%
Krones 10 100.00%
Maaza 8 46.00%
Maintenance Sampat Arul
10 37.00%
Shipping M N Nayak 10 67.00%
Store N K samal 10 100.00%
5.0 5.0
7.0 7.0 7.0 8.0
7.0 7.0
9.0 9.0 9.0 9.0 10
0.0
2.0
4.0
6.0
8.0
10.0
12.0
Actual Target
Tool Box Talk
Quality Shipping Production-1 Production-2 Maintenance Stores CMC Rest All
1 7-Dec-13 Defensive Driving Defensive Driving Defensive Driving Defensive Driving Defensive Driving Defensive Driving Defensive Driving Defensive Driving
2 9-Dec-13 House Keeping House Keeping House Keeping House Keeping House Keeping House Keeping House Keeping House Keeping
3 10-Dec-13Portable Fire
Extinguishers
Portable Fire
Extinguishers
Portable Fire
Extinguishers
Portable Fire
Extinguishers
Portable Fire
Extinguishers
Portable Fire
Extinguishers
Portable Fire
Extinguishers
Portable Fire
Extinguishers
4 11-Dec-13 Safety Policy Safety Policy Safety Policy Safety Policy Safety Policy Safety Policy Safety Policy Safety Policy
5 13-Dec-13 Dealing With Spills Dealing With Spills Dealing With Spills Dealing With Spills Dealing With Spills Dealing With Spills Dealing With Spills Dealing With Spills
6 16-Dec-13 Safety Awareness Safety Awareness Safety Awareness Safety Awareness Safety Awareness Safety Awareness Safety Awareness Safety Awareness
7 18-Dec-13 Safe Work Habits Safe Work Habits Safe Work Habits Safe Work Habits Safe Work Habits Safe Work Habits Safe Work Habits Safe Work Habits
8 20-Dec-13What is Confined
Space?
What is Confined
Space?
What is Confined
Space?
What is Confined
Space?
What is Confined
Space?
What is Confined
Space?
What is Confined
Space?
What is Confined
Space?
9 26-Dec-13Hazard Communication
on Chemical Safety
Hazard Communication
on Chemical Safety
Hazard Communication
on Chemical Safety
Hazard Communication
on Chemical Safety
Hazard Communication
on Chemical Safety
Hazard Communication
on Chemical Safety
Hazard Communication
on Chemical Safety
Hazard Communication
on Chemical Safety
10 30-Dec-13Why Safety is
important?
Why Safety is
important?
Why Safety is
important?
Why Safety is
important?
Why Safety is
important?
Why Safety is
important?
Why Safety is
important?
Why Safety is
important?
DateS#Make Calendar
for TBT
Nominate Circle leader from each Circle
Started Compliance
Measurement by width &
Depth
Safety person participate in one TBT daily
Collect the suggestion
given by members
Audit by safety Manager for
checking involvement
-
Safety Committee Meeting status
Month Jan-13 Feb-13 Mar-13 Apr-13 May-13 Jun-13 Jul-13 Aug-13 Sep-13 Oct-13 Nov-13 Dec-13
Date 18-Jan-13 7-Feb-13 7-Mar-13 3-Apr-13 8-May-13 5-Jun-13 3-Jul-13 7-Aug-13 4-Sep-13 9-Oct-13 6-Nov-13 4-Dec-13
Status a a a a a a a a a a a aPoint Suggested 8 8 7 8 7 9 8 9 9 6 6 6 91
Points Closed 7 8 7 5 5 9 5 7 6 6 2 5 72
% Compliance 87.5% 100.0% 100.0% 62.5% 71.4% 100.0% 62.5% 77.8% 66.7% 100.0% 33.3% 83.3% 79.1%
Total
Safety Committee Meeting
-
Identify requirements as
per std. requirements
Design standard signage's
Fixed at prominent place
Ensure compliance
through Gemba walk
Review the requirement best on suggestion of
associates as well as yearly
Safety Signage's and Hazard Communication
-
100.00 100.00 100.00 95.00 93.00 86.10 85.80
74.10
0.00
20.00
40.00
60.00
80.00
100.00
120.00% PPE Compliance
% Compliance
PPE Compliance Trend
98.52% 97.32% 97.90%
95.01%
98.19%
93.53%
94.11% 94.46%
94.50%
93.94% 95.60% 95.92%
90%
84.00%
86.00%
88.00%
90.00%
92.00%
94.00%
96.00%
98.00%
100.00%
PPE Compliance TargetFinalize the PPE requirement from
individual department.
Compile and follow up from Procurement
dept.. For availability.
Distributed among all Contractor through
HR.
Made excel sheet for tracking of Issued Qty
Weekly PPE Stock circulated by store in
charge
Started Compliance Measurement across 3 shift with standard
format
Review the compliance status and action plan on monthly meeting
Run Campaign on Hand gloves & ear plug use
-
Incident Trend Analysis and CAPA
Cut resistance gloves mandatory at Glass line
PPE Audit Daily
Tracking of PPE availability
Tool Box talk- Daily
Access Control
Man- Machine Segregation
-
SOP developed from corporate
Engaged standard 3rd party
Make Infra for Fulfill requirements
Daily Safety School running with contractor
supervisor
Tool box talk done by supervisor across 3 shift
Various data tracking- PTW, PPE compliance,
Equipment checking etc.
Review daily, fortnightly and Monthly
Audit monthly by Safety Manager
Reward & Recognitions
Contractor Management
Contractor Safety Induction AV started at Gate in multi language
Monthly Review with all participants
Daily Safety pledge
Tool Box Talk
Contractor Management center where we provide Job specific Training
-
CMC- Surveillance
Top 3 Contractor -Jaganath Electrical - Anita Fabricators - Paul engineering
Bottom 3 Contractor - Gear - Quality Facility - Maa Bateswari
Rewarded for the best contractor for the Year-2012 through Factory Inspector
-
0
20
40
60
80
100
120
Total No of Injury No of Injury-Contractor
No of InjuryEmployee
117
74
43 36 18 18
2012 2013
Over all Injury Reduced by
69%
Benefits
GOOD
Description 2012 2013 % Reduction
Total No of Injury 117 36 69%
No of Injury- Contractor 74 18 76%
No of Injury Employee 43 18 58%
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Achieve Safety Excellence through Behaviour Change
Hazard Identification and Risk Assessment
Safety Health & Environment
-
Achieve Safety Excellence through Behaviour Change
Awareness Training and Mock Drill
-
Driver Management Center -Process
DMC
Zero Incidents
Unsafe Driver
Unsafe Vehicle
Unable to Manage
Road Risks
Explain Journey Risks
Any personal problems effecting his driving ability
Explain HCCBPL Violation Policy
Explain emergency contacts and accident reporting procedure
Discuss Road Worthiness
Alcohol Test if suspect
-
DMC - Pre-trip Counseling
Explain Journey Risks
Any personal problems effecting his driving ability
Explain HCCBPL Violation Policy
Explain emergency contacts and accident reporting procedure
Discuss Road Worthiness
Alcohol Test if suspect
Route Adherence
Continuous driving
Breakdown
Physical condition of driver
Rest allowance
Vehicle familiarity
Turnaround Time
Discuss GPS report Observation once available
Explain Safety precaution for truck movement within
the plant
Post Trip Counseling
Journey route risk assessment
-
Achieve Safety Excellence through Behaviour Change
Occupational Health Management
Coca-Cola Associate
Pre Medical Check-Up
Job specific Induction
Area related Health measures
Annual Health Check-Up
Awareness camps
Occupational Health Process For Employees
-
Zone Mapping regarding Health Hazards Health Hazard
High noise area
Toxic Gas Hazard
Chemical Hazard
SUGAR GODOWN EMPTYYARD
Eye Shower
CO2 Fire extinguishers Fire Hydrantas Legends
DCP Fire extinguishers Hazardous Building
M-Foam fire extinguishers Emergency Exit
Water CO2 fire extinguishers PPE BOX
Sand Buckets Water Monitor Hazard To Health
First Aid Box
Prepared by -N K Dubey Approved by -Mohan Singh
Revision Date-16th Jan 2013
PCCRO
OM UPS ROOM
COLLECTIONTANK
READY SYRUP ROOM
CONC. STORE
CROWN STORE
CROWN STORE
PANEL ROOM
CSD FILLING ROOM
ST
OR
ES
ADMIN
CSD PACKAGING HALL
DPG
STP
BOILER ROOM
CHILLING PLANT
AIR COMPRESOOR
DG PANEL ROOM
DG ROOM
RAW WATER TANKS
WA
TE
R P
UM
P
HO
US
E
WTP
READYSYRUP ROOM
WTP CHEM STORE
SAMPLE ROOM
CANISTER FILLING ROOM
CANISTER CIP ROOM
FG W
AR
EHO
USE
WO
RK
SH
OP
ADMIN
CSD PACKAGING HALL
EMPTIES YARD
SHIPPING OFFICE
SE
CUR
IT
Y
HSD AND FO YARD
CO2 YARD
FIR
E W
AT
ER
P
UM
P H
OU
SE TR
AN
SF
OR
ME
R
CAUSTIC YARD
WTP
PANEL ROOM PROD. OFFICE
AC STORE
ETP PANEL ROOM
ETP STORE
ETP LAB
SLUDGE DRYING BED
VERMI
COMPOSTING
PET FILLING ROOM
BLOWER -2
RAW SYRUP ROOM
SU
GA
R G
OD
OW
N
ADMIN
DECAUSTICI
SER
COOLING TOWER
HAZ WASTE STORE
RAIN WATER HARVESTING PITS
FA ROOM
Air
Com
p
Blower-1
KW
FILI
ININ
G HA
LL
CIP
ROO
M PACKING HALL
CIP ROOM
FG WARE HOUSE
NEW WTP
KRONES FILLINGHALL
KRONES PACKING AREA
BLOW MOLDING
KW Blowing RoomMITECO ROOM
COMPRESSOR ROOM
Grass Land
LODI
NG
AREA
QA LAB
RAW WATER TANK
CARTONROOM
SMOKING ZONE
MAAZA PACKING HALLMaaza Filling hall
PULP STORAGE AREA
STORE
PULP
CIPROOM
DRY BASE
CROWN STORAGE
QA LAB
OPEN YARD
BOILER ROOM
LPG STORE
WARMER & LABELLER
CANTEEN
CRECHE
LOCKER ROOM
LAD
IES
RE
STR
OO
M
CONTRACTOR
REST ROOM
CMC
EMERGENCYASSEMBLYPOINT
TWO WHEELER PARKING ZONE
FOUR WHEELER PARKING ZONEAMBULANCE
CULLET WASTE, GARBAGE
-
Before After
Illumination Study
We Study the illumination on monthly basis and based on findings correct it then and there
-
Ergonomic Improvement
Ergonomics: Modify the rejection conveyor for auto drop of rejection- avoid the bending
Change the door position of sugar hoist so manual handling activities of 50
kg bags eliminated
Change the process of caustic ( From Flex to Lie) using in bottle washer to
avoid manual handling
Conveyer extended at Tetra De- Palletizers minimizes physical stress in
job resulting in high productivity levels
Before After
Engineering Control- Kaizen to eliminate ergonomic hazard
Change the opening side and use Forklift in place of manual loading
-
Health Awareness Program
Training on women health
awareness
Toolbox talks on Health topic to contractors
Blood Donation Camp
Health Check Up Camp
-
People Equal Opportunity
Diversity
Outreach Programs
Human Rights
Planet Permit and License Compliance
Bio Diversity
Emissions to Air
Water / Chemical Usage & Discharges
Profit Consistent Profitable Growth
Risk Management
Total Shareholder Return
Environment Management
-
Environment Management
Reduce
Replenish Reuse
Rinse Jet size optimization in Bottle washer
Optimized water consumption for Line Lubrication
Optimize CIP Timing for Syrup Tanks Production planning to optimize
CIPs
Rain Water Harvesting Structures within Plant and across Community (Schools, Offices)
Massive Awareness Campaigns Monthly Water resource
Management Meeting and Gemba walk
Decaustic Plant Recovery improvement to 80%
ETP UFRO Water for Utilities Vacuum Pump Seal cooling Water
Recovery Back Wash water Recovery Condensate Recovery Improvement
to 80% Installation of Anaerobic tower in
ETP
Environment Approach
-
1. 100% utilization of UFRO running
2. Recovery of Treated water (used in
CIP)
3. Kinley Line Loss
WUR : Identified - Opportunity area
Initiation of Vermicomposting
1.61 1.54 1.49 1.45 1.45
0.07
0.06 0.04
1.351.401.451.501.551.601.65
Presently Plant is 74% water neutral ,Target is for 200% water positive by 2020.
3.2 2.79
1.88 1.69 1.6 1.55 1.61 1.45
0
0.5
1
1.5
2
2.5
3
3.5
2007 2008 2009 2010 2011 2012 2013 2014Target
Up gradation of ETP
-
Action taken for Water usage ratio improvement
-
Environment Initiatives
Up gradation of ETP : Introduced fludized bed media system (1000 kg of
BOD / day can be treated)
Commissioning & Successful utilization of Centrifuge for proper handling of sludge
Commissioning & Successful utilization of UFRO- to maintain WUR
Improvement in sludge drying bed and protect the beds via plastic sheets from external factors
Fish Pond Installation of oil skimmer & cleaning activities in collection sump
-
Contribution towards Environment
-
8 8
8
7
8
8
7 6 6
8 8 8
8 8
8
7 7
8
7 6 6
7
8 8
8 8 8
7 7
8 8 8
8 8 8 8
5
6
6
7
7
8
8
9
9
JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC
pH
2011
2012
2013
24 21 22 27 30
22 21 22 33 29 29 27 26 22
27 24 21 22 21 22 28 29
28 32 36
52 48 54
18 20 16 15 16
15 18
10
30
50
70
90
110
JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC
TSS
2011
2012
2013
20 17
16 14
20
12 13 14 13
19 17 17 18 17 16
14 11
15 13 14 13
18
28
19 22
24
28 26 26
11 12 11 9 8 8
22
5
10
15
20
25
30
35
JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC
BOD
2011
2012
2013
PCB Compliance To Waste Water
8.5
6.5
-
2 2 2
3
2 2
3 3 3 3 3 3 3 3 2
3 3
1
3 3 3 3 4 4
4
3
1 1 2
1
2
3
4
5
6
7
8
9
10
JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC
OIL & GREASE
2011
2012
2013
35 31 39 36 52
65
32 36 33 52 50 52 54 52
39 36 34 38 32 36 33
46 54
37
90 100
86 82 84
42 41
46
38 31 30
42
20406080
100120140160180200220240
JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC
COD
2011
2012
2013
PCB Compliance To Waste Water
-
PET Recycling
-
Contribution towards environment
ZERO LANDFILL WASTE Zero waste sent for landfill, all non hazardous solid wastes recycled / co-processed.
-
Now machines at Khurda have life
Dancing doll gives alarm when
safety door is opened in RGB
CSD line
Dancing doll gives alarm when
water level low in 2T boiler
-
Energy Management
Standard KWH sheet
Power tracking sheet
Energy saving kaizens
-
Energy Saving Kaizens
Power-Factor improvement
Boundary Light Automation
PCC-1 & 2 interconnection
PCC-2 auto synchronisation
69 Energy
saving Kaizens
have been
implemented
-
Energy Saving Kaizens in PET CSD 600 BPM Filler
COLD WELL
HOT WELL
CHILLER
MIXTURE
PHE
FILLER
NO PRODUCTION
BEFORE
COLD WELL
HOT WELL
CHILLER
MIXTURE
PH
E
FILLER
NO PRODUCTION
AFTER
SECONDARY PUMP
SECONDARY PUMP
120 KWH
savings
-
Cumulative Cost Saving due to Energy Saving Kaizens
Energy Management Achievements
6.8 8.9
27.2 28.3 30.9 32.4
9.6 7.6 7.2 6.2 4.02 6.6 0.53 1.80
30.89
46.69 61.61
67.01 72.66 73.08 74.27 74.52
74.82 75.01
0.010.020.030.040.050.060.070.080.0
Jan-13
Feb-13
Mar-13
Ap
r-13
May-1
3
Jun
-13
Jul-1
3
Au
g-13
Sep-1
3
Oct-1
3
No
v-13
Dec-13
Savi
ng
in L
acs
Month
Volume in Lacs Cummulative Savings in Lacs
Investment of
12000
-
Classified - Internal use
Sustenance Tool of the Implementation Systems
Developed Routines @ all Levels.
All Leading indicators 5S, BEC, PM & CI is part of Daily Routines.
Daily DMS @ 11: 00 am will be carried out by F.M along with process owners on daily basis covering QSPECS.
Shop Floor DMS will be carried out at beginning of Every Shift involving operating Team.
Interactive session on Shift Performance, Routines Compliance & Pending works.
ROUTINES
Alignment of Expectations.
Common approach on Achieving Business goals. QSPECS
Factory DMS
Common approach on Achieving Business goals. QSPECS
Monitoring & control made more effective
Shop Floor DMS
Effective Upward Down ward Communication.
Involvement of operators in Gap Analysis for immediate corrections.
ROUTINES Factory DMS Shop floor DMS
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Achieve Safety Excellence through Behaviour Change
Coca-Cola SUPPORT MY SCHOOL
12.2 CORPORATE SOCIAL RESPONSIBILITY
Pond before Renovation by HCCBPL Total 74 % water recharged to ground Total 22 water recharge facility created out side the plant
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Model Village Project
Support for Education
Model Village Project - access to health, safe drinking
water, sanitation and education and overall Quality of life
thru self sustaining livelihood projects in 02 villages
Bada Sabar Sahi and Sabar Sahi (SC & ST village).
Access to Health and Sanitation
Drinking Water
Support for Education
Livelihood Support through SHGs 11-14 women in
each of 5 SHGs operating
96% population belongs to Scheduled Tribe
Category
Lowest Literacy rate among nearby villages
High level of poverty (Low Income mostly daily
wage earner -89%)
84 % having only Thatched houses
Absence of basic requirements of Toilet in
households, open area used
Drinking Water
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Safety Day celebration
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Environmental Day Celebration
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Glimpse of Member Secretary, PCB - Odisha & Team 26th May `13
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Award & Recognition
Coca Cola Quality
System Award - 2001
Max Glass Program
Winner - 2003
Max Glass Award of the
Year 2003, HCCBPL
Khurda
Coca Cola Quality
System Award - 2003
Pollution Control
Excellence award -
2005
State Pollution Control
Board Orissa,
Bhubaneswar,
Pollution Control
Excellence award - 2005
CCI Bottler Excellence
Award
Highest Score in
production Rating - 2006
State safety Award
2006
Lowest Severity Rate of
Accident
Excellence in HR ,2007
Orissa
Central Champions
Confrence ,2007
Quality Environment
and safety
Occupational Health
award - 2008
-
Gold certificate of Merit - The
Economic Times Indian
Manufacturing Excellence Award
CII National Award
for Food Safety -2013
Best Kaizen award for
"Supervisor-Manager Level
category". 2013
State Pollution Control
Board Orissa, Pollution
Control Excellence
award - 2005
State safety Award
Lowest Severity Rate
of Accident-2006
Recognitions
Odisha State Food
Safety Award 2012
Quality Environment
and safety Occupational
Health award - 2008
-
Award & Recognition
Integrated Supply Chain
Meet
November 2009 Goa
Best WRM Central
Region, Bhubaneswar
Best Growth in Sparkling Category
2009
Best Performance on RTM score
2009
Best Growth in juice category - 2009
Best Unit in HR Costs /
Productivity 2009
HCCBPL, Central Region ,
HR Meet -2010
Best Factory of the Year - 2011
Max Glass award - 2011
-
Award & Recognition
Safety award 2012 Excellence in
Man Machine Segregation
Odisha State Food Safety
Award 2012 CII JIPM award for "Supervisor
- Manager Level Kaizen"
Supply Chain Seasonal Award - Max PET- High Speed PET(>=430 BPM)
-
Classified - Internal use
Recent Honor
Khurda Plant has been awarded with Odisha State Food Safety Award 2012. The award was given by our Honorable the Chief Minister of Odisha Mr. Naveen Patnaik on 15th Feb 2013.
-
Classified - Internal use
Recent Honor
Khurda WON the CII JIPM award for "Supervisor-Manager Level Kaizen"
-
Award & Recognition
The Economic Times India Manufacturing Excellence
Award - 2013 8th National Food Safety & Quality Summit - 2013
Confederation of Indian Industries (CII) - New
Delhi (3rd 4th December2013)
The ET IMEA, Frost & Sullivan
Gold Certificate of Merit