1. IMPROVING OPERATIONAL EFFICIENCY AT
HECTOR BEVERAGES PVT LTD
A Summer Internship Project by S Prashant Reddy

2. INDEX
• Company Profile
• Assembly Line
• Problem Statement
• Data Collection Method
• Data Analysis
• Findings
• Suggestions

3. COMPANY PROFILE
• Hector Beverages Private Ltd is a manufacturer of Energy Drinks and Fruit Juices
• Started by Neeraj Kakkar, Suhas Misra, James Nuttal and Neeraj Biyani in the year
2009.
• It is currently operating with one plant in Manesar, Gurgaon.
• It manufactures its products under the brands Tzinga and Paper Boat.
• It currently exports its products to countries like Australia, United States of America
(U.S.A), United Kingdom, Nepal, United Arab Emirates (U.A.E) and Canada.

4. CORE VALUES & QUALITY POLICY
Core Values
• Audacity
• Rooting the Underdog
• Integrity
Quality Policy
“We at Hector Beverages Private Limited as responsible corporate citizens shall
conform to regulations and strive to improve the Product Quality, Food Safety and
services continually through optimal Planning and Productivity in a environment
friendly manner to achieve customer satisfaction.”

5. ISO CERTIFICATION
• The company has been certified with ISO 22000:2005 in the year 2013.
• It has been certified for raw materials, storage, dispatch and production
(pasteurization) for the years 2013-2015.
• It has been certified for serving non –carbonated ready to serve fruit beverages and
non – carbonated fruit juice containing caffeinated beverages.

6. • Lemon Mint
• Tropical Trip
• Apple
• Mango
• Mango Strawberry
PRODUCTS
Energy Drink - TZINGA

7. • Aamras
• Aam Panna
• Jaljeera
• Imli Ka Amlana
• Jamun Kala Khatta
• Kokum
• Golgappe Ka Pani
Fruit Juices - PAPERBOAT
PRODUCTS

8. Sugar Dumping
Unit
Raw Syrup Tank
Simple Syrup Tank
Blending Tank-1 Blending Tank-2
Homogenizer
Ready Beverage
Tank -1
Ready Beverage
Tank -2
Pasteurizer
Filler
Post Pasteurization
Tunnel
Cooler Tunnel Air Dryer-1
Air Dryer-2
Packaging Area
Start
End product
ASSEMBLY LINE – FLOW CHART VIEW

9. PROBLEM STATEMENT – ISSUE TO BE RESOLVED
“Decrease in the operational efficiency of the assembly due to the defects in packaging
after the filler station.”
• The defectives noticed listed were
• to date coding not meeting the pre-determined standards
• cap fitting of the pouches not done properly
• leakages from the pouches
• the pouches filled with low volume of the data OR no beverage filled in the pouches.

10. DATA COLLECTION METHOD
• The data was collected on the defectives which occur in packaging after the filler
station. The data was also collected about the production per hour.
• The data about the defectives was collected by manual counting of the number of
pouches at the end of the hour.
• The data about production was collected from the product counter of the date coding
machine.
• In the second stage the data was collected on date coding defects which were related
to misalignment, printing, visibility and absence of date coding.
• This data was also collected through manual counting of the defects at the end of the
hour.
• The data collected during the tenure of the project was on hourly basis.

11. DATAANALYSIS
• In the first stage data was collected about defectives that occur in filler station during
the packaging of the beverage.
• The defectives were as follows
Date Coding not meeting the pre – determined standards.
Cap fitting Not done properly.
Leakages from the pouch.
No beverage filled in the pouch.
Beverage filled in the pouch less than the standard quantity.

12. • The readings collected for the defectives were as follows
Defects (Per Day)
Date Coding Cap Fitting Low Volume No Beverage Leakages Total
224 52 0 19 3 298
23 23 0 17 0 63
50 33 0 30 0 113
346 20 0 22 0 388
243 103 54 24 0 424
714 60 16 31 0 821
85 57 0 17 0 159
378 98 3 9 2 490
1265 177 5 98 2 1547
469 60 2 58 0 589
1010 79 103 27 2 1221
900 136 1 17 0 1054
452 76 102 18 3 651
44 26 13 7 0 90
117 215 6 23 0 361
464 127 12 70 2 675
6722 1284 357 456 29 8848
75.97 14.51 4.03 5.15 0.32

13. Date Coding
76%
Empty Pouch
5%
Low Fill
4%
Cap Fitting
15%
Burst
Defects after Packaging
Date Coding Empty Pouch Low Fill Cap Fitting Burst

14. • By using Pareto principle it was found out that date coding defects and low fill
defects were the defectives which were responsible for the decrease in the
operational efficiency of the assembly line.
• In the second stage data was collected on various defectives that occur in date coding
. They were
Misalignment of the coding.
Printing not being continuous.
Date coding not properly visible due to ink marks.
Missing of date coding on the pouch

15. Date Coding Defects (Per Day)
Alignment Printing Visibility No Date Coding Total
109 3 0 57 169
503 159 82 236 980
116 49 9 30 204
38 3 1 40 82
67 0 1 32 100
150 2 5 128 255
13 0 0 3 16
94 99 9 38 240
323 72 12 97 504
34 89 7 42 172
377 104 26 136 643
276 73 69 291 709
2100 653 221 1130 4104
51.16 % 15.91 % 5.38 % 27.53 %

16. Alignment
51%
Printing
16%
Visibility
5%
No Date Coding
28%
Date Coding Defects
Alignment Printing Visibility No Date Coding

17. • Pareto principle was used to find out the defects which were contributing more to the
date coding defects.
• They were found out to be
Misalignment of date coding.
Missing of date coding on the pouch.
• A fishbone diagram was used to list out the various possible reasons for the
occurrence of the defects.

18. Spouting of the pouches
not done properly.
Pouches inserted in the
wrong direction
Lack of synchronization between filler speed and
print delay time
Pouches inserted into the filler are
exceeding the capacity of the Date Coding
Machine
Temperature in
Filler Station
Power
Fluctuations
Breakdowns
Misalignment
of Date Coding
Alignment of the sensor
being disturbed
FISHBONE DIAGRAM FOR MISALIGNEMENT OF DATE
CODING DEFECT

19. Pouches inserted in the
opposite direction
Lack of synchronization between filler speed
and print delay time
Failure of the sensor to detect the pouches
Number of pouches inserted exceeding
the capacity of date coding machine
Breakdowns
Power
Fluctuations
Missing of the
Date Coding
Alignment of the Sensor
Being Disturbed
FISHBONE DIAGRAM FOR MISSING OF DATE CODING DEFECT

20. FINDINGS• On an average 80 pouches were found to be defective in a batch of 3840
pouches processed in a hour.
• Majority of the defects were date coding defects and they constituted 80
percent of the total defects.
• The defects that were occurring in date coding were
Misalignment of the date coding.
Printing of the coding not being continuous.
Date coding not properly visible due to ink marks on it.
Date coding is missing on the pouches.

21. • The defects which were contributing more found out to be as misalignment
and missing of date coding.
• The root causes for the occurrence of misalignment in date coding were due to
Lack of synchronization between filler speed and date coding machine.
Alignment of the sensor being disturbed.
• The root causes for the missing of date coding were
Failure of the sensor to detect the pouch.
Lack of synchronization between filler speed and date coding machine.
Production helpers inserting the pouches in the wrong way.

22. SUGGESTIONS
The suggestions which were given to the problem of misalignment were to
• Make the position of the sensor fixed with the help of a plate or by any other means
so that the position of the sensor does not get disturbed due to the pressure exerted
by the beverage filling valve and nitrogen filling valve in the process of packaging.
• Making sure that the flow is smooth and continuous so that there would less
variability in the speed of the filler.

23. The suggestions which were given to the problem of absence of date coding were to
• Doing an analysis to find out the reason why the sensor is failing to detect the
pouches in certain instances and taking appropriate action. Frequent maintenance
work of the sensor should be done to make sure that it is working in good condition.
• The production helper who would be inserting the pouches should be cautious while
inserting the pouches and a manual check should be performed before inserting

24. LEARNINGSThe things that I have learnt while working on the project and by observation are as
follows
• The practices that are to be followed in a food processing company to build quality
into the product they manufacture such as checklists for every workstation, clean in
place process etc.
• The working of the assembly line in a beverage manufacturing company and the
methods used to kill micro – bacteria present in the beverage.
• The way in which the production is planned, flow of materials and type of production.
• The problems associated if the assembly line is largely automated.
• The scope for error and the importance of quality in a food processing industry.
• The measures taken by the quality assurance team to provide good quality products
to the customers.
• The practices followed to store the products in the warehouse.