15days Report on Pet line

15days Production and Efficiency Report

Prepared by: Submited to:

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 Chapter One:
Introduction:
Pet line is used for production/filling of plastic bottles with the carbonated beverage of
different flavors. Pet line is also called CSD line. Pet line uses a plastic perform which when
heated and blown gives the desired shaped bottle.

Some of the major machines, equipments and stations with their function are listed below:

1. Blow molding:
This part of pet line is where the actual PET bottle is made. Bottles are molded from the
preform according to the size of the dye. Air pressurized at 40kg/cm2 is used to blow the
heated perform. Currently there are 3 blow-molding machines.

2. Scrambler:
Scrambler is used to store molded bottles which is then placed to hoffer of it and conveys the
bottle to the blower conveyer.

3. Blower conveyer:
This section is used to move the empty bottles around the line. High speed centrifugal fans
are used to generate high air surge which blows the empty bottles in forward to line.

4. Plastic chain conveyer

This transfers the filled pet bottles to other sections i.e. rinser / warmer

5. Carbo-cooler:
This section has the big share of importance in pet line. Carbo-cooler is used for the
carbonation of water and proportioning water with the incoming syrup to make final beverage
and cooling it at the filling temperature.

6. Filler:
This is the part where the empty bottles get converted into pet beverage bottle. Filler fills the
bottles with the beverages and caps. Variable filling speed can be achieved by using the
advanced controls of the filler.

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 7. Warmer:
Warmer is used to warm the bottles to make the bottles firm and ready for labeling. Warming
is done by passing through jets of water at 40oC.

8. Labeler:
This machine is used to put on the beverage label.

9. Coding machine:
This machine codes the batch number, date and time of manufacturing as well as the price in
the bottle.

10. Caser:
This machine packs the finished pet bottle into cases. Here caser from DIMAC company is
used to case pet bottles. It used heat shrinking plastic for packaging.

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 Chapter Two:
Observation and Calculation:
We observed the pet line for 15days and noted all the activity in pet line. Our list of activity
includes Daily production, daily net efficiency, and daily problems encountered during
production etc. we tabulated the production activity and is showed below:

2.1 Daily production table:

Total
Total
Date Working Actual Production Actual Hour
Hour prdn
18th May 24 600ml 2000ml 2250ml 11707 19
19th May 24 0 0 11707 11412 19.5
20th May 24 0 0 11412 10156 19.8
21st May 24 5300 0 4856 9650 22.8
22nd May 24 9650 0 0 10600 21
23rd May 24 10600 0 0 8698 19
24th May 24 8698 0 0 8556 18.5
25th May 24 8556 0 0 8432 19
26th May 24 8432 0 0 9833 21
27th May 24 9833 0 0 11425 19.5
28th May 24 121 0 11304 13320 22
29th May 24 0 0 13320 12888 21.5
30th May 24 0 0 12888 12852 22
31st May 24 0 0 12852 8525 16.5
TOTAL 336 61190 0 78339 148054 281.1

14000
daily production
12000

10000

8000

6000
daily
prodn
4000

2000

0
18th 19th 20th 21st 22nd 23rd 24th 25th 26th 27th 28th 29th 30th 31st
May May May May May May May May May May May May May May

(From the histogram data we can know that in 15days there was highest production done in
28th may with the daily production of 13320cases.)

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 2.2 Daily time consumption and wastage table:

individual time loss individual working hr SD+CIP

600ml 2000ml 2250ml 600ml 2000ml 2250ml

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18th May 0 0 5 0 0 24 4.5
19th May 0 0 4.5 0 0 24 4.2
20th May 2.7 0 1.5 10 0 14 1.2
21st May 1.2 0 0 24 0 0 3
22nd May 3 0 0 24 0 0 5
23rd May 5 0 0 24 0 0 5.5
24th May 5.5 0 0 24 0 0 5
25th May 5 0 0 24 0 0 3
26th May 3 0 0 24 0 0 4.5
27th May 0 0 4.5 1 0 23 2
28th May 0 0 2 0 0 24 2.5
29th May 0 0 2.5 0 0 24 2

30th May 0 0 2 0 0 24 7.5

31st May 0 0 7.5 0 0 24
155 0 181 54.9

2.3 Daily Net and True Efficiency:

Net efficiency and true efficiency of respective dates are calculated using following formulas

𝐴𝑐𝑡𝑢𝑎𝑙 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛
𝑁𝑒𝑡 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 =
𝑇ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛

Where,

𝑇ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛
= (𝑇𝑜𝑡𝑎𝑙 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 ℎ𝑜𝑢𝑟 − (𝑆𝐷𝑇 + 𝐶𝐼𝑃)) ∗ 𝑇𝑎𝑟𝑔𝑒𝑡 𝑐𝑎𝑠𝑒 𝑝𝑒𝑟 ℎ𝑜𝑢𝑟

And,

𝐴𝑐𝑡𝑢𝑎𝑙 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛
𝑇𝑟𝑢𝑒 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 =
𝑇𝑜𝑡𝑎𝑙 𝑊𝑜𝑟𝑘𝑖𝑛𝑔 𝑇𝑖𝑚𝑒 ∗ 𝑇𝑎𝑟𝑔𝑒𝑡 𝑐𝑎𝑠𝑒𝑠 𝑝𝑒𝑟 ℎ𝑜𝑢𝑟

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 Theoretical Net True
600ml 2000ml 2250ml actual daily
daily efficiency Efficiency

0 0 10773 11707 10773 108.67% 86.03%

0 0 11056.5 11412 11056.5 103.22% 83.86%
9900 0 11226.6 10156 21126.6 48.07% 20.23%
11400 0 0 9650 11400 84.65% 80.42%
10500 0 0 10600 10500 100.95% 88.33%
9500 0 0 8698 9500 91.56% 72.48%
9250 0 0 8556 9250 92.50% 71.30%
9500 0 0 8432 9500 88.76% 70.27%
10500 0 0 9833 10500 93.65% 81.94%
9750 0 11056.5 11425 20806.5 110.88% 84.37%
0 0 12474 13320 12474 106.78% 97.88%
0 0 12190.5 12888 12190.5 105.72% 94.71%
0 0 12474 12852 12474 103.03% 94.44%
0 0 9355.5 8525 9355.5 91.12% 62.65%
80300 0 90606.6 148054 170906.6 87% 82%

(From above table we can know that the pet line had an overall Net and True efficiency of
87% and 82% respectively during our 15day observation. The loss in efficiency is due to the
various problems that encountered during the production period.)

2.4 Problems Encountered during our Observation:

Some of the frequent arising problems are listed below:

 Power cut:
During our observation we noted that around 14hrs of total production hours were
halted due to power cut.

 Syrup tank changeover:

During production we observed that the syrup tank runs out of contents after some
time interval. We noted that around 6hr of production time were consumed when
doing a syrup tank changeover.

However we can attempt to mitigate these problems by:

 Increase the volumetric capacity of the syrup tank.
 minimizing syrup wastage
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 Filler problem:

During production we observed that the filling process of filler was halted due to
various factors like tipping off of bottle, etc. this problem is however very less.

 Carbo-cooler problem:

 Labeler :
During our time of observation, labeler had the frequent occurring of problem. Many
pet bottles had to be rejected due to poor labeling. Also there occurred bottlenecking
of bottles coming from the warmer to labeler since labeler wasn’t functioning well.

However we can attempt to mitigate these problems by:

 maintaining proper warmer temperature
 spreading glue on roller properly

• Blow-molding:
Blow molding also encountered some problems during the observation period..

However we can attempt to mitigate these problems by:

• blow air pressure should to maintained at optimal point
• passive operator

• Others:
These include entities like late starting of line, Clean in Place (CIP) etc.

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 2.5 Problem chart:

name: time(minutes) hrs %

Power cut 840 = 14 25%
Syrup tank changeover 370 = 6 11%
Filler problem 100 = 1 3%
Carbo-cooler prob 150 = 2 6%
Labler 70 = 1 2%
Blow-molding 150 = 2 6%
Others(late line start,CIP etc) 47%
total = 26 hr

Pie chart showing frequent problems and theirs occurrence:

power cut

syrup tank
changeover
25%
filler problem

47% carbo-cooler prob

11% labler

blow-moulding
6% 3%
6% others(late line
start,CIP etc)
2%

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 Chapter Three:
Conclusion:
During our 15days observation of pet line we observed that among all 4lines pet line is the
highly efficient line. It is automated line hence it reduces the labor load. The advanced
system; controls make PET line the most user friendly and easily serviceable line among
other line.

But the efficiency is still pushed backward due to various entities. Hence if those entities are
to be eliminated pet line can work smoothly and efficiently providing the company a higher
profit.