Annual Maintenance of Csd Pet line Parimal Tiwari (2013219), Rakesh Nandal(2013229), Riddhi Shah(2013233), Salil Sharma(2013254), Utsav Dubey(2013311), Yash Parekh(2013327)

Submitted to: Prof Sarbjit Singh 9/20/14 Project Management

Contents Project Proposal: ........................................................................................................................................... 2

Project Scope: ............................................................................................................................................... 2

Project Objectives: ........................................................................................................................................ 2

Work Breakdown Structure: ......................................................................................................................... 2

Responsibility Matrix: ................................................................................................................................... 2

Project Scope ................................................................................................................................................ 3

Project Objectives ..................................................................................................................................... 3

Project Deliverables .................................................................................................................................. 3

Milestones ................................................................................................................................................. 3

Technical Requirements............................................................................................................................ 3

Risk Assessment of Annual Maintenance Project ..................................................................................... 4

Time related risks ...................................................................................................................................... 4

A. Time duration of project ............................................................................................................... 4

B. Time consumed during repair ....................................................................................................... 4

C. Conflict in human resource management .................................................................................... 4

Cost Related Risk ....................................................................................................................................... 5

A. Lack Of technical skills of workers: ............................................................................................... 5

Scope Related Risk .................................................................................................................................... 5

A. Failure in achieving targets : ......................................................................................................... 5

Quality Related Risk .................................................................................................................................. 5

A. Turnover Of employees: ............................................................................................................... 5

Table 1. Defined Conditions for impact scales of a risk on Major Project Objectives ............................... 6

Table 2. Probability v/s Impact of above mentioned time, cost, scope and quality related risks of

projects ......................................................................................................................................................... 7

Table 3. Activity Description of Project ........................................................................................................ 9

Figure 1. Gantt Chart Of various Activities Of Project ......................................................................... 10

Figure 2. CPM Diagram ........................................................................................................................ 11

Table 4. Responsibility Matrix Of Project .................................................................................................. 12

Table 5. Work Breakdown Structure & Costs .......................................................................................... 14

Project Proposal: A project proposal is a detailed description of a series of activities aimed at solving a certain problem. In order to be successful, the document should provide a logical presentation of a research idea.

Project Scope: Project scope is the definition of end result or mission of your project a product/service for your client/customer. The primary purpose is to define as clearly as possible the deliverable(s) for the end user and to focus project plans. As fundamental and essential this scope definition occurs, it is frequently overlooked by project managers of well-managed, large corporations. To ensure that the scope definition is complete, following checklist can be followed

Project Scope Checklist 1. Project Objectives

2. Deliverables

3. Milestones

4. Technical Requirements

5. Limits & exclusions

6. Reviews with Customer

Project Objectives: Project objectives are those points which have to be accomplished from the project. The objectives stated in the project must be precise and should be made keeping the stakeholders interest in mind. The objectives must clearly show whats in it for the stakeholders.

Work Breakdown Structure: A work breakdown structure is carried out in order to divide the work elements of a project into smaller sub-categories in order to assign the activities that are needed to be carried out in such a manner that there is clarity on the responsibility and date of completion of activities. WBS is an important project activity that should be carried out to ensure a smooth operation.

Responsibility Matrix:

In this matrix responsibility is assigned to each person responsible for a particular activity in the project. With the help of this matrix project manager could follow up all activities by maintaining the communication to person responsible for their respective activities.

Project Scope

Project Objectives

On time completion of annual maintenance project of CSD PET production line.

To utilize the manpower effectively through allocation of responsibility.

To identify the critical activities associated with various machines.

Project Deliverables

Bottle appearance and durability through blow molder machine maintenance.

Improve the filling level performance by the maintenance of CSD PET Filler.

To improve the capper quality of the bottle through capper maintenance in CSD PET Filler.

To improve upon the packaging attributes in terms of label and carton coding through maintenance of labeler and coding machine.

Milestones

Dissembling of various components of machines (Filler, blow molder, labeler) Dec 8

Maintenance of Base Camp Blow Molder, maintenance of glue drum in labeler, maintenance of filling levers in filler Jan 10

Maintenance of oven section in Blow Holder, maintenance of lift cylinder in Filler, maintenance of cutter in Labeler Jan 25

Assembling of all machines after the maintenance of critical components Feb 3

Dry run of entire production line - Feb 4

Quality results analysis of the dry run Feb 6

Technical Requirements

To increase the overall Owen efficiency to increase the power factor to .96

To increase the blowing efficiency of Blow Molder from 82% to 88%

To increase the pre-form yield from 98.7% to 99.3%

Reducing the rejection due to filling level from Filler machine from 2% to 1.6%.

To increase the Capper Yield from 98% to 99%.

To improve the seven critical factors of packaging from 87% to 91%.

Risk Assessment of Annual Maintenance Project

Below is the scale of risk management in this project. The scale tells us the risk associated with

cost, time, scope and quality. On a scale from 1 to 5 with 1 being a scale of lowest risk and 5 being

the scale of highest risk. The following are the risk associated with this project and their

probability of impact on the below shown scale with respect to dimensions like cost, time, scope

and quality.

Time related risks

A. Time duration of project

Probability 4(High)

Impact 4(High)

This is because of the availability of spare parts which are procured from France (Blow

Molder Sidel), Germany (Filler KHS), Germany (Labeller KRONES) is not confirmed as per

the lead time since these are dependent on external factors like logistics, customs etc. &

conflict in the schedule of OEMs service engineer which are coming from the above

mentioned companies with the companys annual maintenance plan.

B. Time consumed during repair

Probability 3(Moderate)

Impact 3(Moderate)

The technical skills of the operator and maintenance team may not be sufficient enough

for few of the critical maintenance jobs (Example Base Camp Cutter assembly)

C. Conflict in human resource management

Probability 4(High)

Impact 3(Moderate)

It may happen that the same workforce used in maintenance activities for other

production lines as well as maintenance of utility machines (Boiler, Compressor) are being

utilized in this project hence there are huge possibilities of conflict of interests of the

departmental managers (Examples- Production, Maintenance, Quality, Shipping)

Cost Related Risk

A. Lack Of technical skills of workers:

Probability 3(Moderate)

Impact 3(Moderate)

It may happen that new parts which are to be installed get damaged because of

improper handling during installation by the service engineer, operators.

Scope Related Risk

A. Failure in achieving targets :

Probability 3(Moderate)

Impact 5(Very High)

There is a possibility that project is unable to achieve the technical requirements preform

form yield, blow molder, packaging quality, Labeller & Capper yield filler.

Quality Related Risk

A. Turnover Of employees:

Probability 2(Low)

Impact 3(Moderate)

There is a possibility that service engineer of OEM, production engineer, quality officers,

fitters or operators may leave the organization which though has a low probability but

has a moderate impact on the project.

Table 1. Defined Conditions for impact scales of a risk on Major

Project Objectives

Project Objective

1

Very Low

2

Low

3

Moderate

4

High

5

Very High

Cost

Insignificant Cost

Increase 20% cost

increase

Time

Insignificant time

increase 2 days increased

2-5 days

increased

5-10 days

increased

>10 days

increased

Scope

Scope decreases

barely noticeable

Minor areas of

scope affected

Major areas of

scope affected

Scope reduction

unacceptable to

sponsor

Project end item

is effectively

useless

Quality

Quality degradation

barely noticeable

Only very

demanding

applications are

affected

Quality reduction

requires sponsor

approval

Quality reduction

unacceptable to

sponsor

Project end item

is effectively

useless

Relative or Numerical Scale

Very High

Probability

High

Probability

T-C

T-A

Moderate

Probability

T-B/C-A

S-A

Low

Probability

Q-A

Very Low

Probability

Very Low

Impact

Low

Impact

Moderate High Very

High

Table 2. Probability v/s Impact of above mentioned time, cost,

scope and quality related risks of projects

Impact

Probability

Activity Activity time Predecessor 1 Predecessor 2 Predecessor 3

Rotory 3

Brake Unit 2 Rotory

Base Cam 2 Brake unit

Transmission Body 2 Base Cam

Bell Nozzle Cylinder 2 Transmission Body Brake Unit

Base Mold Support 2 Bell Nozzle Cylinder Brake Unit

Stretching Cylinder 1 Base Mold Support

Transfer Arm Assembly 2 Stretching Cylinder Base Cam Brake Unit

Oven Section Hydraulic 2 Transfer Arm Assembly Base Cam

Console Assembly 1 Oven Section Hydraulic

Compensation Valves 2 Console Assembly

Preblow Valves 2 Compensation Valves Console Assembly

Mold Locking 2 Preblow Valves Brake Unit

Star 2

Lift Cylinder 2

Lever 1 Lift Cylinder

Rinser 2 Lever Star

Valve Maintenance 2 Rinser

Capper 2 Valve Maintenance Lift Cylinder Lever

Support of Tulip 2 Capper Rinser Lift Cylinder

Electrical 2 Support of Tulip Capper Rinser

Mechanical Operations 3 Electrical Support of Tulip

Level Probe 2 Mechanical Operations

Vacuum Drum 5 Level Probe Electrical

Hose Pipe 8 Vacuum Drum Level Probe

Infeed Worm 9 Hose Pipe Vacuum Drum

Glue Roller 6 Infeed Worm Hose Pipe Level Probe

Main Block 2 Glue Roller

Vacuum Drum 1 6 Main Block

Centering Turret 3 Vacuum Drum Hose Pipe Electrical

Cutter Assembly 6 Main Block Vacuum Drum

Vacuum Distribution 2 Cutter Assembly

Glue Roller 1 5 Vacuum Distribution

Heater 5 Glue Roller Cutter Assembly

Applicator 2 Heater

Brake Unit 1 3 Applicator

Guide 4 Brake Unit Mold Locking

Air Conveyor 6 Guide

Blower 4 Air Conveyor

FRL Unit 2 Blower

Head Assembly 5 FRL Unit

Article Conveyor 6 Head Assembly

Table 3. Activity Description of Project

Warmer Conveyor 3 Article Conveyor

Conveyor Bend 4 Warmer Conveyor

Warmer Comb 3 Conveyor Bend

SU System 4 Warmer Comb

Dry Run 1 Warmer Comb Glue Roller 1 Brake Unit 1

Quality Results 2 Dry Run

Figure 1. Gantt Chart Of various Activities Of Project

Figure 2. CPM Diagram

Table 4. Responsibility Matrix Of Project

Project Team

MACHINES Raj KumarSarvan Lal BahadurMahendarPuranvasi S.Rawat HemantLalit PradeepSanjayArvind R. Tiwari Sri NarayanProdu. OfficerShift Engg.Quality Officer

Blow Molder

1.1 Rotory R S S S

1.2 Brake Unit S S R S

1.3 Base Cams R R S S

1.4 Transmission Body R S R S

1.5 Bell Nozzle Cylinder S R S R

1.6 Base Mould Support R R S S

1.7 Stretching Cylinder R S S S

1.8Transfer Arm Assembly S S S R

1.9Oven Section Hydraulic R R S S

1.10Console Assembly S S R R

1.11 Compensation Valves S R S S

1.12Preblow Valve Air Leakage S S S R

1.13Mold Locking assembly R R S S

2. FILLER

2.1Star R S

2.2Lift Cylinder S R

2.3Lever R S

2.4Rinser R R

2.5Valve Maintenance S R

2.6Capper S R

2.7Support Of Tulip R R

2.8Electrical R S

2.9Mechanical Operation S R

2.10Level Probe R S

3. LABLER

3.1Vacuum Drum R R S

3.2Hose Pipe R S S

3.3Infeed Worm Assembly S S R

3.4Glue Roller assembly R S S

3.5Main Block S R R

3.6Vacuum Drum Assembly S R R

3.7Centering Turret Guide Assembly R R S

3.8Cutter assembly R S S

3.9Vacuum Distribution S S R

3.10Glue Roller Assembly S R S

3.11Heaters S S R

3.12Applicator S R R

4. UNSCRAMBLER

4.1Brake Unit R S

4.2Guide (2lt) S R

4.3Air Conveyor R S

4.4Blower R S

4.5Frl Unit Air Leakage R S

5. CASER

5.1 Head Assembly R S

5.2Article Conveyor S R

6.WARMER & CONVEYORS

6.1Warmer Conveyor R S R

6.2Su System S R S

7.DRY RUN

7.1Blow Molder Trial Run R S

7.2Filler Trial Run R S

7.3Labler Trial Run S R

7.4Unscrambler Trial Run R S

7.5Caser Trail Run S R

8.QUALITY RESULT R

MACHINES DAYS COST

1. DISASSEMBLING 8 400000 TOTAL COST 6350000 2. MAINTENANCE OF MACHINES 47 5500000

2.1 BLOW MODLER 1500000 2.1.1 Rotory 200000 2.1.2 Brake Unit 150000 2.1.3 Base Cams 150000 2.1.4 Transmission Body 200000 2.1.5 Bell Nozzle Cylinder 300000 2.1.6 Base Mould Support 200000 2.1.7 Stretching Cylinder 100000 2.1.8Transfer Arm Assembly 100000 2.1.9Oven Section Hydraulic 40000 2.1.10Console Assembly 15000 2.1.11 Compensation Valves 20000 2.1.12Preblow Valve Air Leakage 12000 2.1.13Mold Locking assembly 13000

2.2 FILLER 1000000 2.2.1Star 200000 2.2.2Lift Cylinder 150000 2.2.3Lever 100000 2.2.4Rinser 40000 2.2.5Valve Maintenance 30000 2.2.6Capper 30000 2.2.7Support Of Tulip 350000 2.2.8Electrical 30000 2.2.9Mechanical Operation 20000 2.2.10Level Probe 50000

2.3 LABLER 700000 2.3.1Vacuum Drum 15000 2.3.2Hose Pipe 1700 2.3.3Infeed Worm Assembly 40000 2.3.4Glue Roller assembly 30000 2.3.5Main Block 50000 2.3.6Vacuum Drum Assembly 100000 2.3.7Centering Turret Guide Assembly 120000 2.3.8Cutter assembly 18000 2.3.9Vacuum Distribution 200000 2.3.10Glue Roller Assembly 20000 2.3.11Heaters 19000 2.3.12Applicator 86300

2.4. UNSCRAMBLER 400000

2.4.1Brake Unit 120000 2.4.2Guide (2lt) 40000 2.4.3Air Conveyor 50000 2.4.4Blower 150000 2.4.5Frl Unit Air Leakage 40000

2.5. CASER 600000 2.5.1 Head Assembly 400000 2.5.2Article Conveyor 200000

2.6.WARMER & CONVEYORS 1300000 2.6.1Warmer Conveyor 800000 2.6.2Su System 500000

3. ASSEMBLING 9 400000

4.DRY RUN 1 50000 4.1Blow Molder Trial Run 12000 4.2Filler Trial Run 7000 4.3Labler Trial Run 5500 4.4Unscrambler Trial Run 22000 4.5Caser Trail Run 3500

5.QUALITY RESULT 2

Table 5. Work Breakdown Structure & Costs

Summary The above data is an Annual Maintenance Project of CSD Pet Line, one of the beverage line in PepsiCos

manufacturing plant in India. The production ends in the month of November and the entire beverage

line goes for the maintenance work which lasts for 2 months. The annual maintenance is considered to

be one of the most important task because the quality of maintenance done will help the plant to perform

as per the AOP Targets for the upcoming year, as well as this time is the only time when the demand of

the product is low due to chilling winters and the company can afford a shutdown of 2 months.

The maintenance of the line is done in an old traditional way which generally depends on the experience

and knowledge of few of the operators and production engineers. In this project we have applied few of

the theoretical knowledge of Project Management in order to change the style and reduce the projects

risk. The entire work is divided into small packages and these work packages are then allocated to

Operators and Production Engineers in terms of Primary Responsibility and Secondary Responsibility. The

various risks associated with the project are analyzed and they are segregated in terms of Impact and

likely hood of occurrence.

The network diagram shows that the entire project will take 67 days and there are 20 critical activities

which needs special attention as they fall on the Critical Path, these activities must be given special

importance in order to prevent the maintenance to extend beyond the deadline.