Project REPORT

ON

To eliminate the Minor stops in

overhead conveyor
(Report submitted for the vocational training during
sixth semester Electrical Engineering)
AT

Submitted By :
Naba Kishore Sarkar
Regd No- 1011018011
Mechanical Brach ( Sec-C)
ITER ( SOA University) BBSR

UNDER GUIDANCE
OF
Mr.:Arul Ram (Mentor)
Mr. T.Rajya.Shesu (Guide)
Mr. Pabitra Pradhan (Guide)

Certificate

This is to certify that the project report entitled To eliminate

the Minor stops in overhead conveyor submitted by Mr.
Naba Kishore Sarkar, Regd No 1011018011 7th semester of
the degree of Bachelor of Technology in Mechanical
Engineering at Institute of Technical Education & Research,
Bhubaneswar is an authentic work carried out by him under
our supervision and guidance in the summer training
conducted by HINDUSTAN COCA COLA BEVERAGES PVT
LTD.
To the best of our knowledge, his conduct was satisfactory.

Mr. Mohan Singh

Date:
Place: Khurda

Factory Manager
HCCBPL ,
Khorda

Acknowledgement
I would like to convey my sincere gratitude to the director and
management of HINDUSTAN COCA-COLA BEVERAGES PRIVATE
LIMITED,KHURDA for providing me to undertake industrial training
from 20.05.2013 to 20.07.2013.I am very thankful to Mr. Mohan
Singh , Factory Manager(HCCBPL), for his kind support and
encouragement during the training period .I would also like to
extend my thankfulness to other officers namely Mr. Md. Rumman
(Manager OE), Mr. Arul Ram KB(Manager TPM), Mr. Mathurananda
Nayak(Incharge Shipping), Mr. N.K Dubey(Manager Safety) & all
other officials of HCCBPL khorda who have given their full cooperation during my entire training tenure.
I wish to thank my supervisor Dr. D.N.Thatoi , Prof. and Head
Mechanical Engineering Department, ITER Bhubaneswar and
I am sincerely thankful to Dr. H.C.Das, Prof. Mechanical Engineering
Department, ITER Bhubaneswar for his valuable and kind
suggestions.
I am extremely grateful to Mr. T.Rajya.Sheshu (Production Manager )
HCCBPL for his persistent support and advice during the project
work.
I am also thankful to Mr. Pabitra Pradhan (Team Leader in
Production RGB Line), HCCBPL Khurda for his help during project
work.
Special thanks to my family members, without their blessings and
support, I could not have reached this destination.
Last but not the least, I wish to place my deep sense of thanks to
my friends especially to Mr. Debashis, Line Executive(RGB) and Mr.
Amar pahi for their cooperation and critical suggestion during my
project work and studies.

Place: Bhubaneswar

Naba Kishore sarkar

Declaration

We do hereby declare that this project entitled, To

eliminate the minor stops in Overhead conveyor has
been carried out by us in coordination with our project
supervisor Mr.T.Rajya Sheshu for the fulfillment of our
summer training. Any other institution for financial rewards
or any other purpose has not submitted this work. We do
further declare that the fact of data and figures presented in
the project are to the best of our knowledge & belief.

Place: HCCBPL Khurda

Date:

Arul Ram
(Planning Manager)

Pabitra Pradhan
(Team leader
Production Dept)

Contents

1. Project charter
2. Introduction
3. Process mapping
4. Downtimes check list
5. Downtimes chart
6. Problems
7. Fish bone analysis
8. Causes
9. Facts
10. Improvement
a. Sensor
b. Initial loading bay flush
11. Dry floor
12. Fork lift analysis chart

PROJECT CHARTER
List of downtimes of overhead
conveyor
Project Name:

Project #:

Project Start/End Dates:

To eliminate the Minor stops in

overhead conveyor
30 May 2013

Project Lead:

Naba kishore sarkar Executive Sponsor:

Under Guidence of:

T. Rajya . Sheshu
Pabitra Pradhan

Arul Ram

Project Costs: (include required capital, expenses)

- /-

- Expenses:

Mission/Project Overview:

To find out the main problems behind

the downtimes of over head
conveyor
Objectives: (include beginning & ending KPI's)

Net Benefits:

To improve SLE of RGB from current level

In Scope:

Reduce downtimes

OE Tools to be used:

Out of Scope:

RGB overhead conveyor

Assumptions:

Risks & Constraints:

Number of product changes will remain

same or less than current ratio.
Project Milestones:

Define : 30 June 2013

Measure : 15 July 2013
Analyze: Causes of downtimes
Improve : Reduce the downtimes
Control : Break down

Dependencies:

Project Lead Time: (Total time required to implement) 2Months Other Key Stakeholders & Areas Affected:

Approvals:

Project Lead:
Area Lead:
Finance:
Executive Sponsor/
Steering Committee:

Naba Kishore Sarkar

Date:
Date:
Date:
Date:

Introduction :
HISTORY OF COCA-COLA COMPANY:Coca-Cola is a carbonated soft drink sold in stores, restaurants and vending
machines in every country except Cuba & North Korea. Dr. John Smith
Pemberton, a pharmacist from Atlanta, Georgia developed the syrup that would
become the basis for Coca-Cola. The Coca-Cola formula and brand was bought
in 1889 by Asia Griggs Candler who incorporated the Coca-Cola company in
1892 in Atlanta, Georgia. The company offers more than 500 brands in over 200
countries or territories and serves over 1.7 billion serving each day. The company
only produces syrup concentrate which is sent to various licensed bottlers
throughout the world. The bottlers produce finished product in cans and bottles
from the concentrate in combination with filtered water and sweetners and sell,
distribute the products in various retail stores and vending machines.
HINDUSTAN COCA-COLA BEVERAGES,PVT.LTD:Hindustan Coca-Cola beverages is the largest bottling investment group (BIG) of
the Coca-Cola company in India. It has 24 bottling plants in various states spread
across India.
VISION:To make every Indians first choice of refreshment available within easy reach.
MISSION:To build a consumer-driven, customer-focused, profitable, sustainable & society
responsible business in India.

PRODUCTION( HCCBPL produces) :-Sparkling beverages (Coca-Cola, Diet coke, Thumps up, Sprite, Limca ,Fanta,
Soda)
-Still beverages [ maaza, minute maid (pulpy orange, nimbu fresh,
mango 100% juices range of fruit flavoured drinks)]
-Water (Kinley, Bonaqua)

ACHIEVEMENTS & AWARDS:HCCBPL is encouraged in its drive for excellence in all spheres by the recognition received
from various stakeholders such as
Best water management award by CII (2006,2007,2008,2009)
Pollution control excellence award by SPCB, Odisha (2005)
Best employer award (2005) & Best environment practice award (2012) by APPCB,
Andhra Pradesh.
Golden peacock award (2006,2008,2009)
Best employer award for employing Physically Challenged personnel & Best organization
of Uttar Pradesh (2006) by govt. of Uttar Pradesh.
National safety council award by govt. of India.

Plant description :
The plant consists of six production lines along with two water treatment plants and one
effluent treatment plant
The production lines are :Maaza line(RGB)
140 BPM PET(CSD)
Kinley line
600 BPM PET(CSD)
Tetra pak(Maaza/Minute maid)
RGB(CSD)

Maaza line(RGB) :This line produces Maaza which is a juice based product from Coca-Cola industry.
Glass bottles consisting 200ml/250ml beverage are being produced here.
This line produces 600 bottles per minute.

140 BPM PET(CSD):This line produces carbonated soft drinks like Coca-Cola, Thums up, Fanta, Limca &
Sprite.
PET bottles of 2ltr,2.5ltr,1.25ltr are being produced in this line.
The capacity of this line is 140 bottles per minute.

600 BPM PET(CSD):-

This line produces carbonated soft drinks like Coca-cola, Thums up, Fanta, Limca
& Sprite.
PET bottles of 400ml,500ml,600ml are being produced here.
The capacity of this line is 600 bottles per minute.

Tetrapak:This line produces Maaza and Minute maid Mango.

Each pack contains 200ml by volume.
Line capacity is 400 packets per minute.

Kinley :ThiThis line produces carbonated soft drinks like Limca, Coca Cola, Thums up,
Sprite & Fanta.
This line produces 300ml and 200ml glass bottles.
Capacity of this line is 600 bpm.
line produces packaged mineral drinking water.
Capacity of each bottle is 1 ltr by volume.
The plant produces 140 bottles per minute.
s line produces packaged mineral drinking water.
Capacity of each bottle is 1 ltr by volume.
The plant produces 140 bottles per minute.

RGB (CSD) :This line produces carbonated soft drinks like Limca, Coca Cola, Thums up, Sprite
& Fanta.
This line produces 300ml and 200ml glass bottles.
Capacity of this line is 600 bpm.

Overhead Conveyor is a form of Conveyors consisting of a continuous

chain running beneath a continuous, stationary, flanged rail. Individual
carriers spaced equidistant along the length of the conveyor are suspended
from the chain. The chain pulls the carriers. Vertical support is derived from
the fact that the carriers are also connected to a small trolley with wheels that
roll cross sections, trolleys and carriers. A few common carriers include a tray,
platform or simple hook. A less common alternative to the chain drive is a
worm drive. Overhead or ceiling hung conveyor is often used to maximize
space, sort, buffer, and distribute, and is one of the most economical methods
of conveying while maximizing floor space.
Overhead conveyors which move automatically through the production
process on a rail are used for the transportation of many components. A
certain minimum distance is required so that components do not collide with
each other during the transport.
The overhead conveyor comprises a main track and a branch track
connected to the main track in a switch point, the tracks having a shape of a
box-like beam with a longitudinal slit in its bottom flange for suspending a
trolley carriage, the carriage supporting a rocking lever having at its ends
guiding rollers, the operation of the switch point being safeguarded via tiltable
tongues arranged on the lower flange of the track and cooperating with slide
shoes provided on the ends of the rocking lever, and by means of locking rails
attached to the side walls of the track to lock the rocking lever in the desired
angular position; the ends of the rocking lever further support safety noses
each having an inclined surface of a length sufficient for bridging the gap
between the ends of the inclined tongues and the beginning of the locking rail
when the slide shoe still engages the end portion of the safety tong.

Process mapping

Empty
yard( Loading
Bay)
Slope conveyor(upward)

Horizontal

Spiral conveyor

Slope conveyor(downwar

Horizontal

Uncaser

Downtimes check list

DATE

SHIFT

PROBLEM

ACTION TAKEN

ROOT CAUSE

DOWNTIME(
mins)

30-May

chain link bend

4 Link cutted

over age & lack

of lubrication

31-May

wear & tear

31-May

broken crate
stucking

1-Jun

1-Jun

1-Jun

chain out (slope

conveyor)

Chain
shortened

2-Jun

chain out

sprocket
changed

2-Jun

3-Jun

10

4-Jun

11

5-Jun

12

5-Jun

13

7-Jun

14

8-Jun

15

11-Jun

16

11-Jun

17

12-Jun

18

12-Jun

19

13-Jun

SL. No

Chain
shortened
crate released
broken crate
and conveyor
problem
restarted
sporcket
chain out
changed
spiral conveyor
strip was
strip damage
replaced
chain out

sprocket
damage
more chain
slackness
Worn out due to
lack of
lubrication
Sprocket
damage

spiral conveyor
new strip fitted Due to life span
strip damage
cutted and
chain out
wear & tear
fitted
Worn out due to
Chain
chain out
lack of
shortened
lubrication
new modified
chain out from
heavy dirt
collar was
idler
particles
fitted
sprocket
Sprocket
chain out
changed
damage
Chain
chainout
wear & tear
shortened
Chain
lack of
chain out
shortened
lubrication
sensor problem
sensor was
OHC stops
due to heavy
cleaned
rain
reset and
Frequent start
OHC trip
restarted
and stop
sprocket
Sprocket
OHC chain slip
changed
damage
Wear striped
chain out
repaired
damaged
Wear striped
chain out
repaired
damaged

14
4
10
8
4
12
14

8
24
12
6
4
3
4
24
6

Problems faced in overhead

conveyor (Top ten)
1)Chain out from
sprocket
2)Motor trip
3)Chain link bend
4)Cable short
5)Channel break
6)Collar roller damage
7)Bearing damage
8)Strip damage (spiral
conveyor)
9)Sensor malfunction
10)Broken crate

Fishbone analysis for

Overhead conveyor failure

METHOD

MAN

Technic
al skill

Trainin
g

Chain link
bend

Cable
short

Lack of
lubrication &
life span of
strip

Channel
break

Strip
damage in
spiral
conveyor

Lack of
lubricatio
n

Chain out
from
sprocket

Lack of
awareness

Bearing
damage

Frequent
use & lack
of
lubrication

Broken
crate

MATERIA
L

Overh
ead
conve
yor
stops

MACHIN
Classified - Internal use
E

Motor
tripped
Fluctuatio
n of
voltage
supply

Over load &

bearing
failure

Sensor
malfunctio
n
Heavy dirt particles &
heavy rain

Causes of chain
out
Lack of lubrication
Wear and tear
Over load ( sensor
malfunction)
Sprocket worn out
Heavy dirt particles
Frequent start & stop
( Fluctuation of power)
Broken crate stuck
Life span

Stainless steel flat chains slides over

plastic plates to get less friction and
obtain better slide.
*

Classified - Internal use

Improvement to reduce downtime

Before

After

No protection from rain

New SS cover for sensor

to avoid heavy rain

Improvement to reduce downtime

By this modification heavy dirt particles coming with

crate will get flushed & SS cover will avoid water
contact with motor.

Pictures captured during breakdow

Strip broken on spiral conveyor SS flat chain link broken

Classified - Internal use

BEFO
RE

AFTE
R

Classified - Internal use

BEFORE

AFTER

Classified - Internal use

BEFORE

AFTE
R

Classified - Internal use

Participated in taking the observation for

determining forklift efficiency.
Day 2 Fork Lift No : 14 (Double capacity ,
battery operated )
Date : 25 May 2013
Driver Name : Mr Kesar
Gajendra
Shift:
A
Sl.
No.

Time

Workdone1

Workdone2

Workdone3

Workdone4

Remarks

Was there in
Engine starts at
Shifting of
ware house till
NA
NA
6:30am
palates till 7am
6:30am
At 7:00 started
Only shifted few
7:007:55-8:00 No
2
working in ware
NA
NA
palates which were
8:00
work
house
not fully loaded
8:00Switched off
Went for
Lifted few fully
3
NA
NA
9:00
engine at8:15
breakfast
loaded palates
Went to
Engine switched
9:00- Engine starts at
4
maintenance yard off for battery
NA
Did sourcing work
10:00
9:00
at 9:15
change
At 10:02 engine
10:30-10:35
Here he worked in
10:00starts after
10:08- 10:10 took
10:35-10:55
5
roamed without
production, sourcing,
11:00
battery
rest
again took rest
any work
dustbin shifting etc
changed.
Worked in
11:40-11:50
11:00Worked for
This 1hr he worked at
6
sourcing of
mango pulp

12:00
production
a good speed
empty RGB
drums shifting
12:007
NA
NA
NA
NA
NA
13:00
NA
NA
NA
NA
13:00- NA
8
14:00
Initial running hour= 10107
Total no. palates =121
Final running hour =10111.5
Total no. cases=6079
Total running hour= 4.5hr
BY- Naba Kishore Sarkar
1

Tot
al
Palat cas
es es
Total

6:007:00

NA NA
11 581
3

146

14 856

19 976

74

##
##

NA NA
NA NA

Conclusion

Introduction :
A conveyor system is a
common piece of mechanical &
electrical handling equipment
that moves materials from one
location to another. Conveyors
are especially useful in
applications involving the
transportation of heavy or bulky
materials.