URS Production Dashboard - R2

Operation Dashboard – RFQ & KPI's
Production Dashboard
Request For Quotation
& Key Performance Indicators
Company PepsiCo Foods Vietnam
Site Binh Duong Plant
Country Vietnam
Project Name Production Dashboard
URS Revision B
Revision date 22 September 2023
Revision History
Date Revision Originator Change Description
04-Aug-2023 A Le Quoc Han First issue
30-Sep-2023 B Nguyen Hoang Vu Clarify more
This document is confidential and proprietary. No information shall be disclosed, copied, or used
for any purpose other than for which it is specifically furnished without the prior written consent
of PepsiCo.
Contents
Revision History ............................................................................................................................................................ 1
1. Project Information ................................................................................................................................................4
1.1. Correspondence & Invoice Address .............................................................................................................4
1.2. Delivery........................................................................................................................................................4
1.3. Confidentiality .............................................................................................................................................5
1.4. Language ......................................................................................................................................................5
1.5. Standards & Specifications ..........................................................................................................................5
2. Scope of Supply .....................................................................................................................................................5
2.1. Introduction ..................................................................................................................................................5
2.2. Project Overview..........................................................................................................................................5
2.3. Program Management ..................................................................................................................................6
2.4. Works in vendor scope .................................................................................................................................7
2.4.1. Hardware .................................................................................................................................................7
2.4.2. Dashboard ...............................................................................................................................................7
3. System Inputs and Dashboard Requirements ........................................................................................................7
3.1. Production output .........................................................................................................................................7
3.2. Line Efficiency .............................................................................................................................................8
3.3. Material Efficiency.......................................................................................................................................9
3.4. Utility consumption.................................................................................................................................... 10
4. Commercial Details ............................................................................................................................................. 11
4.1. Site Access and Conditions ........................................................................................................................ 11
4.2. Timelines.................................................................................................................................................... 11
4.3. Post Project Support ................................................................................................................................... 11
4.4. Training ...................................................................................................................................................... 12
4.5. Manuals and Documentation ...................................................................................................................... 12
Penalty clause ...................................................................................................................................................... 15
Payment condition ............................................................................................................................................... 15
Insurance.............................................................................................................................................................. 15
4.6. Project Stage Gate Definitions ................................................................................................................... 16
5. Design .................................................................................................................................................................. 17
5.1. Construction Standards .............................................................................................................................. 17
5.2. MES (SCADA) Software ........................................................................................................................... 18
5.3. PLC Software (Version issue） ................................................................................................................. 18
5.4. Maintenance ............................................................................................................................................... 18
5.5. Installation .................................................................................................................................................. 19
5.6. Tagging and Identification ......................................................................................................................... 19
5.7. Systems Interfaces (I/O and Ethernet TCP/IP） ........................................................................................ 19
6. Requirements for Communication to the External Information System – MES .................................................. 19
7. Control System Hardware.................................................................................................................................... 20

7.1. Proposed Network ...................................................................................................................................... 20
7.2. Control Panels ............................................................................................................................................ 20
7.3. Field Equipment ......................................................................................................................................... 20
7.4. Internal Data and Display ........................................................................................................................... 20
7.5. Emergency Stops / Controlled stop ............................................................................................................ 20
7.6. System or Power Failure ............................................................................................................................ 20
8. Performance ......................................................................................................................................................... 21
8.1. Key Performance Indicators for New Equipment ...................................................................................... 21
8.2. Guarantees.................................................................................................................................................. 21
9. Key Performance Indicators - KPI's .................................................................................................................... 21
9.1. Operating Environment .............................................................................................................................. 21
9.2. System Efficiency ...................................................................................................................................... 21
9.3. System Waste ............................................................................................................................................. 21
9.4. Downtime ................................................................................................................................................... 21
9.5. Quality........................................................................................................................................................ 22
9.6. Product Change Overs................................................................................................................................ 22
9.7. Cost of Ownership ..................................................................................................................................... 22
9.8. FAT ............................................................................................................................................................ 23
9.9. Machine Validation Testing ....................................................................................................................... 23
9.10. Start-Up and Fault Recovery ...................................................................................................................... 24
9.11. Maintenance Requirements ........................................................................................................................ 24
10. Site Impact ...................................................................................................................................................... 24
10.1. Buildings / Access to site ........................................................................................................................... 24
10.2. Existing Equipment and Operation ............................................................................................................ 24
10.3. Utilities ....................................................................................................................................................... 24
10.4. Plant Environment...................................................................................................................................... 24
10.5. Noise Control ............................................................................................................................................. 24
11. Acceptances and Handover ............................................................................................................................ 25
1. Project Information
This document covers the complete minimum requirement for Improve Auto-Multipack machines Project.
This document however does not limit the contractor to make changes in the design concept to meet
acceptance criteria of project.
1.1. Correspondence & Invoice Address

All correspondence should be addressed as follows (via e-mail):
Main project contacts:
Name Nguyen Hoang Vu Name Luong Minh Tan
Position Production Manager Position Engineering & Maintenance Manager
Tel Tel
Mobile +84 902470392 Mobile
Email Vu.Nguyenhoang@pepsico.com E-mail tan.luongminh@pepsico.com
All information is to be copied to:

Name Phan Minh Man Name Varadid Singsombut
Design and Project Management
Position Procurement Manager Position
Manager
Tel Tel
Mobile Mobile + 668 1931 6759
Email Man.PhanMinh@pepsico.com E-mail Varadid.Singsombut@pepsico.com
All Invoices and Paperwork should be sent to:
PepsiCo Foods Vietnam Company. Head Office

Zone 01 + 16, Floor 17, Vincom Building, 72 Le Thanh
Ton, District 1, Ho Chi Minh City
1.2. Delivery
Delivery should be through a pre agreed delivery schedule to the following address:
PepsiCo Foods Vietnam Company. Binh Duong Plant

No. 3-4-5, Plot CN2, No.2 Street, Song Than 3
industrial area, Thu Dau Mot City, Binh Duong.
1.3. Confidentiality
This project should be considered as confidential and not discussed with a third party unless written
permission is given by the Project Manager of PepsiCo.
A mutual confidentiality & non-disclosure agreement must be signed by PepsiCo and the Supplier and
returned with tender.
Intellectual property & reference site restrictions. The content of this user requirement and existence of the
project are confidential. It is a requirement that all documents and drawings are only made available to
persons and organizations that have a clear requirement to have access for the purpose of tendering or
implementing this project alone and that any participation in the project is not made known to unconnected
third parties.
1.4. Language
All quotations to be in English, documentation and software should be in English.
All site installation works, operation manuals, training documentation and operator interface, HMI Graphics
should be provided in English.
1.5. Standards & Specifications

The project must comply with the following PepsiCo standards:
• PepsiCo EHS Standard 50 – Machine and
Environment Health and Safety
Equipment Safety V3.02 pdf
• Electrical Standards April 2016.pdf
Electrical and Control Specification
• Control System Standards April 2016.pdf
• Mechanical Engineering Standards October
Machinery Standards
2014.pdf
Management of Works • Management of Works March 2012.pdf
In addition, all equipment and installation procedures must comply with Good Manufacturing Practices
(GMPs) and be compliant with inspection protocols performed by American Institute of Baking (AIB) &
complying with MESS V3.02 Equipment Safety Audit requirements to be conducted by a competent 3rd
party vendor assigned by PepsiCo Thailand.
Any deviations from the above standards must be agreed in writing by both parties in advance prior to order
placement. Deviations from PepsiCo standards following order placement will be at the expense of the
supplier unless otherwise agreed by PepsiCo.
2. Scope of Supply
2.1. Introduction
The purpose of this document is to define the end user requirements for the design, manufacturing,
installation, commissioning, and project management of building an operation dashboard for Binh Duong
plant.
2.2. Project Overview

PepsiCo Foods Vietnam Company (PFVC) has the plan to build database and visualize operational
performance, as real time as possible, in order to monitor and analyze for improvement.
Figure 1: Examples of a production output dashboard
There are some key performance indicators we want to monitor:

- Production output: volume, SKUs ratios, % plan achieves, etc.
- Line efficiency: TE %, NE %
- Material: usage, efficiency
- Utility: water usage, electricity usage, and LPG usage
- Wastage: waste chips, potato waste, etc.
With the real-time and exact information, PFVC can optimize the operation and aim to manufacturing
excellence.
2.3. Program Management

o Program Management is governed by the Management of Works March 2012.pdf.
o Provision of a designated Project Manager from conception through commissioning and handover.
This person to be the single point of contact for PepsiCo throughout the project.
o On receipt of order complete a plant layout drawing for all parties to agree conceptual layout before
manufacture – all designs must include good operator access to all equipment for both production
and maintenance needs.
o Design safety risk assessment must be developed and presented to PepsiCo for approval in-line
with MESS V3.02 standards. MESS compliance will be validated by a 3rd party.
o Training of the system at Operator and Engineering levels.
o Delivery of system performance to required KPI level.
o Provide technical support and post project support.
o Completion of all agreed project snags / required enhancements.
o Timing schedule to be presented in Microsoft Project format and pdf or Microsoft Excel format.
o Post-project support – warranty for 12 months after handover, including remote support during
office hours.
o All new assembly/schematic drawings to be supplied in AutoCAD .dwg and Adobe .pdf formats.
2.4. Works in vendor scope
2.4.1. Hardware
Utility measurement equipment:
- Water: install at least 8 flowmeters for key areas which consume most water
- LPG: utilize current flowmeters and connect database.

- Regarding flowmeter brand name, Ecozen is preferred.
HMI for inputting production information: there should at least 2 HMI at Process and Packing areas.
Sensor/camera to capture line running or stoppage: depends on technical proposal of vendor.
CCTV to visualize operation performance: at frontline area and production office.
2.4.2. Dashboard
The dashboard is designed by vendor to fulfil the requirement of PFVC. It must be available on both
computer and mobile phone. The program should be friendly for PepsiCo employee, both maintenance
and operation team, so that we can modify if having error or need to be updated.
3. System Inputs and Dashboard Requirements
3.1. Production output

The volume is measured by various units, such as cartons, polybags, kilograms. PFVC will share the SKU
information to convert between different units: gram/bag, bag/carton, etc.
The volume could be measured by full automation or manual. Vendor should propose both solutions then
PFVC can make appropriate decision.
- Option 1: measure output by an automation mechanism, and it must be able to capture different
SKUs on line.
- Option 2: employee input mannually number of output on HMI
Note: at the same time, there could be maximum 4 different SKUs. They are same flavor product but
different pack sizes, different carton (or polybag) configuration. Detail information of all products, SKUs will
be shared in project implementation.
Table 1: Example of different PC SKUs
Weight of Bags per Bags per Weight of Weight of Carton

SKU
pillow bag Multipack carton Multipack (Gr) (Kg)
6M 32Gr 10 160 320 5.12
10M 54Gr 10 100 540 4.32
20M 95Gr 10 40 950 3.8
30M 150Gr 5 30 750 4.5
10M
45Gr 10 100 450 4.5
MAX
20M
75Gr 10 40 750 3.0
MAX
The program must be open for user to modify or add new recipe when having new products, SKUs.
3.2. Line Efficiency

At PepsiCo, we are tracking line efficiency by TE indicator, True Efficiency.
- Actual production is measured as above.

- Theoretical production is based on:
o Scheduled hour: manually input startup time and shutdown time,
o Fryer capacity: calculated by Solid (%) factor. Operator will manually input Solid when
changing potato lot. The formula to calculate fryer capacity based on Solid will be shared
later,
o % seasoning: different by flavors (products), manually input by operator.
Figure 2: Example of PC line daily TE% in Sep'23
Time loss:
Line stoppage should be captured automatically by an appropriate solution proposed by vendor. Definition
of every stoppage will be classified manually by operator on HMI.
The dashboard will have a waterfall chart for all line stoppage, measured by % or hours.
Figure 3: example of PC line machine downtime waterfall in Sep'23
3.3. Material Efficiency

There are different materials for every finish good unit. Depends on different products (lines), the materials
are various.
PC Frypack (FP) Extrusion (EX)
Raw material Potato Pellet Powder

VO (vegetable oil) VO (vegetable oil) VO (vegetable oil)
SSN (seasoning) SSN (seasoning) SSN (seasoning)
Film Film Film
Pack material PP bag PP bag PP bag
Carton LDPE poly bag LDPE poly bag
In PC line, we have over 10 products with different flavours. It means that there are over 10 different SSN
codes and over 10 various film codes, while other materials are same.
Theoretical usage of materials is calculated directly by actual production output and bill of material (BOM),
while actual usage is manually input by operator when finish every production batch.
3.4. Utility consumption

We need to monitor consumption of 3 utility resources: Water, Electricity and LPG. Their usage needs to
be measured real time by using data from the measurement equipment. Combine with actual production
output, we can track the utility consumption per ton, i.e., Lit/kg for Water or kWh/kg for Electricity.
Utility usage could be analyzed by all consumption points. Just for example, we need to understand water
usage at every different area in our plant: PC line, Canteen, Agro area, etc. This is quite important for us to
identify problem and have solution for improvement.
Figure 4: Example of current water usage tracking

4. Commercial Details
4.1. Site Access and Conditions

The installation area sits within a PepsiCo manufacturing plant, working 24 hours a day, including
weekends.
Site access will be allowed within the normal operating conditions for that site, ensuring that all contractor’s
work comply with PepsiCo Health and Safety policies, food safety regulations and must be free of potential
contamination.
All contractors working on site must be Safe Contractor accredited.
Any works that require an outage on a production line must be highlighted at tender stage to enable PepsiCo
to plan accordingly. This must also include all works associated with any re-configuration of case conveyors
to enable manual palletizing throughout the main project installation phase. Following agreement of the
project timescale plan, all outages must be agreed one month in advance.
For reference, all manufacturing lines will normally have a planned 16-hour dayshift-based production
outage every 4 weeks for the purpose of plant maintenance. Every effort should be made to align project
outage needs to planned production outages in order to minimize the impact to site capacity (as long as
this does not have a negative impact of deliverable timelines)
Any requirements for electrical, pneumatic or nitrogen isolation must be agreed with site in advance.
The Installation will be conducted by local contractors under the supervision of Suppliers / Vendors while
Commissioning to be executed by Vendors / OEMs / Principal Contractors Only. All Installation Supervisors
& Commissioning Engineers must be ENGLISH literate.
4.2. Timelines
Timelines should reflect all aspects of the project before, during and after installation. Timelines of project
should be as follows.
o Obtain proposal by early 15th Oct 2023
o Finalize and purchased order by 22nd Oct 2023
o Detailed design signing off by 30th Oct 2023
o Equipment Receipt at Site before 30th Nov 2023
o Successful Installation and Commissioning by 15th Dec 2023
Weekend working time and any disruption to production should be confirmed with site. The site may insist
on weekend and night-time working during the installation and commissioning period, and this should be
clearly identified within the costing i.e., cost and timeline for 7 day / 12 hours dayshift working versus 7 days
/ 24 hour working. Any constraints with being able to execute 24-hour working must be highlighted at the
tender stage. Working hours and consecutive working days need to be managed to ensure no employees
are placed at risk – the successful company will be expected to review working hours with PepsiCo at the
bi-weekly review meetings.
4.3. Post Project Support

Support should be available during normal office hours; site attendance to review or action responses are
required within the same working day.
Out of office hours contacts should be available to facilitate 24 hour per day operations.
This cover should apply for the duration of the warranty period, as a minimum.
4.4. Training
Full operating and maintenance training for the equipment and program should be provided for site
personnel as part of the quotation. Vendor needs to provide formal training calendar specifying need &
timelines of the training so that resources can be released in order to attend the trainings.
4.5. Manuals and Documentation

A full documentation package should be supplied for the prescribed content and timeline for the whole
contract. Appropriate stage payments will only be made following completion of each stage and receipt of
appropriate documentation to support. If alternative stage payments terms are agreed with the supplier,
the documentation required for each payment does not differ from that identified within the Management of
Works.
The vendor is responsible for providing all documentation in an “as-built” condition at the end of the project.
It is the vendor’s responsibility to update any manuals given to PepsiCo if changes are made during the
installation, start up, or commissioning process.
The vendor will manage, design, specify, procure, write software, document, test, deliver, install and
commission all aspects of this project, including certification to all relevant standards.
o The supplier shall prepare diagrams, layouts and working drawings showing arrangement of plant,
equipment, and steel supports. These together with specifications of major bought out items shall
be submitted to PepsiCo for 'Approval in Principle' prior to commencing manufacture.
o The vendor shall provide detailed connection point for all utilities including electrical and
compressed air intakes and advise quantities & consumptions.
o The contractor must provide all documentation associated with the role of Principal Contractor i.e.
Develop and manage the Health and Safety
o Construction Phase Plan. Following approval to commence works, non-generic / task specific
method statements and risk assessment to be submitted for all phases of site work. Site work shall
not commence until the method statement has been approved by the Principal Contractor.
o Approval by the purchaser of any such document will not relieve the contractor of his responsibilities
for any errors, omissions, or discrepancies therein.
o The contractor shall submit a bar chart program showing key events and dates to the purchaser for
approval within two weeks of order placement. The contractor shall indicate the time required for
submission and checking of drawings, making allowance for the key program dates.
o The contractor shall provide fortnightly progress reports to the purchaser detailing current activities
and items completed, compared with the program.
o Project management to maintain the project time plan and coordinate installation and
commissioning with site personnel and other suppliers / co-vendors, while taking Full responsibility
of the Design, Manufacturing, Installation & Commissioning being done by Other Supplier / System
Integrators / Control Engineers / Co-vendors when engaged by the Principal Contractor or Project
Awardee.
o Overall system layout, design, and architecture
o Specification of all hardware, software, cabling (electrical and network), and mechanical installation
requirements.
o Procurement, delivery and install of all necessary software, hardware, cabling, and equipment
(except where specified).
o Specification, coding, and configuration, testing of all software (except where specified) and
equipment.
o Design, documentation and facilitation of FAT, SAT, and the commissioning “go-live” method and
program. It may not be necessary for multiples of the same equipment to be tested. This should be
agreed in advance with the project team.
o The SAT testing will consist of thorough performance testing, I/O testing and full in depth testing of
the Emergency Stop/ Safety system which will be fully documented and placed within the technical
file.
o Training and documentation on system build, recovery, and application software structures such
as: OITs, PLCs & Controllers Program Back Ups, their Passwords, Software CDs and Licenses,
etc.
o Electronic copies of documentation to be supplied in a site modifiable format (Word).
o Drawings and documentation should be presented as detailed in PepsiCo Engineering
specifications.
o The supplier should provide Standard operating Procedures (SOPs) covering.
o Equipment start up (steps and sub steps)
o Equipment shut down (steps and sub steps)
o The vendor will supply a recommended spare parts list for all the supplied equipment including
associated costs.
o Documentation and Drawing that shall be provided will be in accordance to The Management of
Works 2012, including but not exclusively:
o Functional Design Specification – must be approved by Region Engineering Team before
development commences.
o FAT document – must be approved by Sector Engineering. Includes methods and schedule.
o SAT document – includes testing all connected devices and communications with the ‘real’
computer systems. Functional testing is a subset of the FAT. References the FDS. Includes
methods and schedule.
o Technical folder which will contain Risk assessments for the machines and integrated line, safety
calculations via SISTEMA or PASCAL, All CE marking details, safety device data sheets and
overall safety category of the machine/line.
o A Tag Import Sheet – detailing the New Tags to be uploaded to the Server and Client apps.
o Hard copies of Bill of Materials
o Operational Instruction Manuals along with detailed “screen shots” for ease of understanding which
will be supplied in hard and soft copies.
o Isometric & Exploded Views of Mechanical Assemblies with their Part Numbers & Part Descriptions.
o Maintenance Instruction Manuals / Spare Parts Listing in PepsiCo standard Criticality format –
inclusive of OEM / Supplier Original part number.
o Planned / Preventative / Predictive Maintenance Schedules - In PepsiCo standard criticality format
and based on FMEA study of installed asset base / Commissioning Data / Set-up Data
o Tag Export sheet – highlighting redundant tags which have been removed.
o A List of additional SQL scripts, triggers, procedures etc...
o Mechanical layout drawings
o Soft copy of the PLC ladder logic fully documented.
o Soft copy of the PLC Topology fully documented.
o 2 Hard copies of Electrical schematics and 2 Soft copies of Electrical Schematics on DWG and
PDF
o A soft copy of variable speed drives settings. (Where applicable)
o P.M. Schedules / Commissioning Data / Set-up Data
o Documentation should have test certificates issued to BS7671 after installation but prior to
commissioning.
o PC Rebuild/ Re-install procedures if applicable.
o Equipment start-up and shutdown (steps and sub-steps).
o Equipment operation (steps and sub-steps) with expected centerline activities ranges and limits.
o Must include description of equipment controls cause and effect as well as alerts, errors and fault
messages.
o Equipment changeover (steps and sub-steps)
o Equipment troubleshooting (80/20 rule) (steps and sub-steps).
o Set-up and navigation for HMI or PC’s.
o Operator safety, lock-out/tag-out and warnings and hazards (steps and sub-steps).
o Identification of parts for the purpose of ordering spares.
o Equipment diagrams/illustrations/photos/etc. with critical parts, knobs, buttons, switches, E-stops,
etc. called-out/labelled.
o Access control matrix for HMI
o List of Software licenses E.g., RSView, RSlogix 5000, ABB Robot applications (Runtime
/Development)
o Life Cycle management document for all major hardware’s and software’s
o Network Architecture
o Detailed IO Loop testing reports
o Detailed parameter list of Electrical Motors configured with VFD’s
o Installation Qualification & Performance qualification document
o Critical Component Analysis (CCA) report
o Access control matrix for HMI
o List of Software licenses E.g., RSView, RSlogix 5000, ABB Robot applications (Runtime
/Development)
o Life Cycle management document for all major hardware’s and software’s
The vendor shall issue a design package to PepsiCo at tender, design acceptance, delivery and final
acceptance stages as detailed below:
Acceptance
Acceptance
Delivery
Tender
Design
Final
Equipment layout, plan & elevation 2D AutoCad ✓
Equipment model, 3D Single part native format ✓
Full Simulation of the system (logic and flow) ✓
Process Flow Diagram (PFD). Excel ✓
Control Panel Layout. AutoCad ✓
Field Wiring Schematic. AutoCad ✓
Functional Design Specification (FDS). Word ✓
PLC code fully annotated. ✓
Utilities Requirement (peak and running). Excel ✓ ✓
Floor Loadings. AutoCad ✓ ✓
Operator Manual. Adobe .pdf ✓
Maintenance Manual. Adobe .pdf ✓
Recommended Spares List. Excel ✓
Cost of ownership, first 3 years. Adobe .pdf ✓

Training schedule. Word ✓
Program of Works. MS Projects ✓
Project Management Structure. Adobe .pdf ✓
Construction Phase Plan. Adobe .pdf ✓
Designers Risk Assessment. Excel ✓
Functional Safety Design Specification (FSDS). Word ✓
CE compliance certificate. Adobe .pdf ✓
Commissioning and test records. Adobe .pdf ✓
Pre-Delivery Inspection (PDI) records ✓
Factory Acceptance Test (FAT) records ✓
Snagging List, complete and approved ✓
Final Acceptance Certificate ✓
Penalty clause
In case project is delayed by more than one day then suppliers, shall pay to Pepsi-Cola a Penalty at the
rate 0.5% of the Contract Sum per day and up to the maximum of 10% of the Contract Sum. The above
penalty clause has been imposed in order to keep the basic timing, which is absolutely vital for the
completion of this important project. (Details to be discussed)
Payment condition
1) 20% upon purchased order with 60 days credit term.
2) 20% upon details design approval with 60 days credit tern
3) 30% upon FAT with 60 days credit term
4) 20% upon installation complete with 60 days credit term.
5) 10% upon project completion and sign off with 60 days credit term.
Insurance
Without limiting any other obligation or liability of Contractor under the Agreement, Contractor agrees that
upon execution of the and throughout its entire effective period hereof, Contractor will procure and maintain
at all relevant times insurance coverage, at its sole cost and expense, with limits and conditions not less
than those specified below.
(a) Commercial General Liability Insurance: Written on an occurrence form, including but not limited to
premises-operations, property damage to third parties, public liability, legal liability for Contractors, with
limits of at least $1,000,000 per occurrence and $2,000,000 in the aggregate.
(b) Commercial General Liability Insurance: Written on an occurrence form, including but not limited to
products liability for Contractors, with limits of at least $1,000,000 per occurrence and $2,000,000 in the
aggregate.
(c) Worker’s Compensation Insurance: Contractor must comply with the benefits afforded under the laws
of Thailand and shall ensure that at all times during the term of this Agreement has adequate Worker’s
Compensation Insurance as prescribed under the laws of the Kingdom of Thailand.
(d) Property /All Risks Insurance: with full limit covering 100% of Contract value of the property.
(e) Professional Liability Insurance: with limits no less than $2,000,000 covering Errors & Omissions of
Provider arising from the acts when providing or failing to provide professional services. Coverage may be
written on a claims-made coverage form and shall be maintained for a period of no less than three (3) years
following the completion of work or must contain an extended reporting period provision.
General Requirements:
1. Contractor’s purchase of insurance will not in any way limit Contractor’s liability under this Agreement.
All coverage must be written on an occurrence basis and must be maintained without interruption from the
date of this agreement until the date of termination of this agreement as far as available and subject to
commercially reasonable terms.
2. Should any of the above described policies be cancelled before the expiration date thereof, the issuing
insurer will promptly mail 60 days written notice to the certificate holder, but failure to do so will impose no
obligation or liability of any kind upon the insurer, its agents or representatives.
3. Waiver of subrogation by insurer in favor of PepsiCo only insofar as Contractor shall indemnify and hold
PepsiCo harmless against product liability claims by virtue of legal liability in respect of bodily injury in
connection with Contractor`s business and to the extent to which the injury or damage was caused by
Contractor.
4. The coverage amounts set forth above may be met by a combination of underlying and umbrella policies
so long as in combination the limits equal or exceed those required.
5. The Contractor and any subcontractor will provide Buyer with certificates of insurance evidencing the
insurance required prior to commencing any work.
4.6. Project Stage Gate Definitions

Stage Gate Definition
1 Written order received by Vendor Order received and accepted
PepsiCo receipt and approval of documentation in design
2 Acceptance of design proposals
acceptance chart
3 Pre-delivery inspections Inspection report and photographs of progress
4 Factory acceptance test Operate and simulate the control system
Goods unloaded and on site, or held at intermediate store
5 Delivery of equipment to site
ready for delivery
Fully mechanically and electrically complete and
6 Installation
connected to all applicable utilities
Safety systems verified, device testing, functional tests
7 Engineering commissioning
with hand-fed product
8 Take over Equipment available for PepsiCo site operators safe use
PepsiCo operator and maintenance crew training including
9 Training safety, maintenance, operation including scheduling and
sanitation
Commissioning of the system to identify all installation and
10 Process commissioning
operational problems
System robust producing product for retail sale with no
11 Production start-up
significant outstanding snags
12 Performance tests KPI test validation
13 Final acceptance Snagging list cleared, documentation received, KPI's met
Prior to the commencement of powered start-up and commissioning of the system, all areas identified in
the ‘Approval to Commission’ document needs to be completed in full and signed by the relevant PepsiCo
representatives. It is the responsibility of both PepsiCo and the Supplier to complete their areas of
responsibility in preparation for sign-off.
Likewise, all areas of the ‘Approval to Operate’ document need to be completed in full and signed by the
relevant PepsiCo representatives. It is the responsibility of both PepsiCo and the Supplier to complete their
areas of responsibility in preparation for sign-off.
5. Design
5.1. Construction Standards

The installation must comply with the latest PepsiCo Management of Works Document and Electrical
Engineering Standards, together with PepsiCo’s EHS Standard 50 – Machine and Equipment Safety -
Version 3.02.
For conveyors, no sprocket-chain drives to be used. Motor to be directly coupled with the shaft and all the
drive shafts must be 360 degrees guarded.
Any non-compliance to the standards must be noted and reviewed with PepsiCo before any orders are
placed. The supplier must issue a Deviations Document whereby all proposed deviations to the PepsiCo
standards, this URS and the KPIs document are listed by document type.
The packing hall and dispatch area are dry areas with no wash down sanitation. The equipment must meet
all American Institute of Bakers (AIB) requirements for sanitation.
The following materials shall not be used:
- Glass of any kind. This includes gauge aids, filter bowls, sight glasses, and glass-fibre insulation.
- Cadmium and cadmium-plated materials. This includes fasteners.
- Asbestos in any form.
- Chromium-based paints or primers.
- Mercury. This includes thermometers and switches.
A Functional Design Specification (FDS) should be provided describing how the machine is designed to
deliver the KPIs within the KPI document.
Utilities
The vendor should take responsibility for identifying the electrical and compressed air requirements for the
equipment and provide these requirements to the site at the design stage to confirm availability. The system
should have capability to operate at 4.5 bar air pressure, Vendor needs to provide actual CFM required in
order to run the complete palletizer system.
Every effort should be made by the supplier to reduce the environmental impact, including such features
as automatic power down when the equipment is not used for a specified period of time, one single point
of energy shutdown, Energy efficient EFF3 low consumption motors coupled to a K type gearbox as a
minimum standard, power meters on each sub-panel, Energy efficient lighting and motion sensors/dimmers
Site Compressed air will be at a Plant level & flow rates will vary dependent on location of main supply.
Vacuum systems must also be limited, motor driven (not compressed air) and powered down when not
required for specific periods of time. Any vacuum connecting pipe work must be kept to a minimum length.
Modularity
All machinery must arrive at site on pallets or skids. The skid shall be removed quickly and easily so that
the equipment can be positioned, anchored, and utilities connected. No external loose parts or cables shall
be shipped with the machine. The installation plan must be completed and agreed with the site prior to FAT.
Equipment shall be protected adequately against damage in shipment. Sling points, lifting lugs or other
material handling areas must be clearly marked. The machine will remain the responsibility of the vendor
until the machine is in its final position.
The supplier should agree with the site in advance the methods and timelines associated with testing and
ensure enough time is allowed. Control panels shall be machine-mounted unless agreed in advance with
the project team.
Machine Footprint
The equipment shall not exceed layout following guideline in Appendix A.
Electrical cabinets
All electrical cabinets should be accessed via a key specified by PepsiCo (standard keyed entry); PepsiCo
proposes Air-conditioned electrical cabinets with slope on the Top in order to minimize dust accumulation,
vendor need to share GA drawings with PepsiCo before placing final order.
Cable calculations with colour coding should also be submitted at the design stage. All cable entry into the
Electrical cabinets would be sealed tight with proper glanding, all Electrical cabinets must be provided with
dual earthing/grounding mechanism. All Cables carriers/trays has to be sealed end to end.
Cleaning
The conveyor equipment is to be installed in a dry wipe area, outside of the product zone. Cleaning methods
will include vacuuming, wiping with fast drying alcohol wipes.
Equipment should be designed to provide easy access to all areas for cleaning with no specialist equipment
required and minimal labour considering Hygienic Engineering concepts in mind while designing the
complete system.
The design shall consider and wherever possible, minimize or exclude all crevices, cracks, pockets, joints,
ledges and similar which can accumulate dirt and dust, are difficult to clean, and may potentially promote
the growth of bacteria, fungus, or infestation.
5.2. MES (SCADA) Software

See section 6.0 for more information.
5.3. PLC Software (Version issue）

See Electrical Standards April 2016.pdf and Control System Standards April 2016.pdf
5.4. Maintenance
Consideration must be given to adequate space to install, maintain, clean and unblock the system whilst
maintaining system functionality. The supplier should advise at the design stage on any new spares the
site should hold (spares value to be less than 1% of capital purchase value and based on a criticality profile
in line with PepsiCo standard). The site should be advised at the design stage whether any special tools or
lifting gear is required for maintenance.
Standard parts must be identified via clear data cleansed descriptions detailing all relevant technical and
original supplier information.
The supplier is to present an optimized maintenance strategy utilizing techniques which may include
maintenance by cycles, by operational hours, by predictive techniques as opposed to traditional time-based
approaches. Vendor to provide.
- list of complete spares list inclusive of critical spares with their sources, cost etc. along with
maintenance schedule.
- drawings of vendor designed/mfd wear components and PepsiCo can choose either to go to TEAL
or go outside.
- Specs and sources of all proprietary components
- guarantee that components are of latest generation.
- confirmation from the vendors of critical components for spare/service support throughout the
lifetime of the equipment.
- to provide SLA for spares/service support to PepsiCo. (delivery/response time)
5.5. Installation
The vendor shall provide an installation guide two weeks after the agreed design for installation contractors
and site to follow.
Installation guide must include build methodology, equipment weight, equipment foot locations, lifting
locations, floor loading, electrical service requirements, mechanical services requirements, compressed air
service requirements, and any other essential information to install the equipment.
The supplier must agree in advance and detail the materials access routes & the operational / people route
throughout installation.
Vendor will facilitate unloading of equipment and machinery at factory. Unpacking will be done in presence
of vendor only. Entire risk of unloading and unpacking to be of vendor responsibility.
5.6. Tagging and Identification

The installation shall comply with the current PepsiCo Engineering Specifications, which are available on
request.
Redundant (unused) tags which are identified as part of the scope of the project are to be removed from
the IO server application and Client application as to prevent false alarms being generated.
5.7. Systems Interfaces (I/O and Ethernet TCP/IP）

The vendor shall be responsible for all interfaces from and to existing equipment, including any free issue
items. This should include any modifications to ensure the overall system performance.
Ethernet switches and network design needs PepsiCo approval.
6. Requirements for Communication to the External Information System – MES

The machinery must communicate with a factory system that will collect and process performance data
about the machinery. The attached MES Specifications v1.0.pdf document specifies the requirements. As
a preview, the machinery programming must be designed to be able to give the following information
through the communication system. Each piece of information is assigned a tag, with numbers
corresponding to the status or other necessary information.
Machine Status (tag in PLC code, sent to MES)
Must be in one of the following at all times:
• Status 1 = Running
• Status 2 = Starved (for primary incoming product) i.e., bags into a case packer
• Status 3 = Blocked
• Status 4 = Faulted
• Status 5 = Starved (for secondary incoming product) i.e., cases into a case packer
First-Out Stop Cause (tag in PLC code, sent to SCADA)
• Unique number assigned to any event that can cause a transition into Status 4
• The number is latched and sent to SCADA and not cleared until the machine is back in one of the
other states.
Centrelines (tags in PLC code, sent to SCADA)

• Variables that can be changed in a machine by an operator
• These variables are captured at predefined events i.e. at each stop
This data is collected in a Data Concentrator (Allen Bradley PLC). A Cisco router is positioned between
the equipment (Packaging Rooms Only) and the data concentrator allowing all of the machine code to be
the same.
7. Control System Hardware

Preferred equipment is detailed within the PepsiCo Management of Works Document and Electrical
Engineering Standards. The hardware brand should be approved by PepsiCo in advance and listed in the
quotation.
7.1. Proposed Network

Internal PLC network: Ethernet
There is a requirement for data collection from packaging into the MES system
External: Connected to our corporate network via Ethernet IP
The IP address is to be issued by the local Controls Systems Specialist
7.2. Control Panels

The main control panel should be made from material as per Electrical Engineering Standards March 2012
The Plant Specifications are: Control voltage 24V DC
Supply 380V AC, 3 phase 4wire, 50Hz supply
KVA rating to be provided during Design
Power
Acceptance.
7.3. Field Equipment

All field devices shall be clearly labelled and identified with device number matching the wiring diagrams.
7.4. Internal Data and Display

The PLC shall accumulate and display a set of current and cumulative data (Standard Data and fault
recording).
All data collected to be viewable locally by operator.
Fault history shall store the last 1000 faults.
See OIT Data - Palletizer rev1.pdf for full requirements on performance data screens.
7.5. Emergency Stops / Controlled stop

Emergency stop systems shall comply to the MESS V3.02 standard.
7.6. System or Power Failure

All equipment must be protected against electrical supply spikes & surge protections. Electrical System has
to be protected against Phase prevention safety relay.
8. Performance
8.1. Key Performance Indicators for New Equipment

Section 9 below, details the KPIs the machine / system must achieve. Any deviations from these KPIs must
be agreed with the site in advance of order placement through using the PepsiCo approved deviation
document.
8.2. Guarantees
Refer to the PepsiCo Management of Works 2012. The Supplier shall guarantee all of the items comprising
the equipment against defective workmanship and/or materials for a period of at least 12 months from the
date of successful completion of the Acceptance Test.
9. Key Performance Indicators - KPI's

This URS details the KPIs the palletizing system must achieve. By providing a quotation, the vendor is
confirming compliance with these KPIs unless agreed in writing by PepsiCo.
9.1. Operating Environment

The machine will be required to run for 24 hours/day and remain in operation 24 hours/day until such time
specified by the manufacturer for purposes of recommended maintenance and sanitation. The system shall
be capable of meeting all KPI’s concurrently and at all times between planned maintenance and sanitation
schedules.
9.2. System Efficiency

System Efficiency MEASURE
The Premade machine shall have smooth continue running by 120 hours (5 days) with 5% allowance for
any correction, re-set up, fine tuning, breakdown etc. due to itself, not by other machines such as bag maker
(input to Premade) or case packer (output from Premade).
9.3. System Waste

System Waste MEASURE
Single bag (snack pack) waste: This is the percentage of single bags that are damaged by the system.
The system shall have a system waste of less than 0.01%
System Waste (Total good bags entering the ‘System’ – Total good bags leaving the 'System') * 100
METHODOLOGY = Total good bags entering the ‘System’
PP multipack waste: This is the percentage of PP multipack that are damaged by the system (torn, wrong
sealing…) or contain wrong number of products inside, which we have to tear the PP and repack product.
This waste figure should be provided by the PLC and be available on the system control panel as Case
Waste as a percentage figure based on the above calculation method.
9.4. Downtime
Downtime MEASURE
The equipment is required to function with no more than 1% downtime due to failures measured over each
3-month period following Site Acceptance Test up to the end of the 12-month warranty period. The supplier
to be responsible for resolving issues associated with this KPI throughout the warranty period.
Downtime METHODOLOGY
Downtime should be logged as part of the standard shift data collection and calculated as a percentage of
total operational time.
9.5. Quality
Quality MEASURE
The PP multipack must contain exactly number of single bags inside, following the recipe of product. The
system should have function to detect and reject these defected PP multipack.
The PP multipack must not be torn or sealed incompletely, which could lead to dropping out product.
The single bags product inside PP multipack must be ensured quality also, not be damaged by malfunction
of premade machine.
Quality METHODOLOGY
The Product Quality levels on the input to the system shall be determined by sampling the product from the
current PepsiCo bagmaker prior to the new Premade machine.
The Product quality level on the out-feed of the system shall be determined by sampling the PP multipack
contained exact number and good single bags inside. For example, based on table in 3.2 Specification, a
PP multipack 6M has 10 single bags, it must not contain only 9 bags or 11 bags.
The sample size should be an agreed representative sample.
9.6. Product Change Overs

Product Change Over MEASURE
Changeovers between different SKU’s and / or case or pallet sizes must be able to be completed in less
than 15 minutes by one operator. Changeovers should be automated with no change parts or mechanical
adjustments.
Product Change Over METHODOLOGY
The change over time shall be determined as the final case produced on the current run, to the first case
of a continuous flow of new product produced whilst KPIs are being achieved. The personnel conducting
the changeover shall have the appropriate skills required. All materials shall be available. This time should
be recorded for a minimum of 5 change overs and should include the most challenging changeovers.
9.7. Cost of Ownership

Cost of Ownership MEASURE
The total cost of all consumables, maintenance and service items inclusive of Vendor supplied labour for
the whole system should not exceed 3.0 % of the initial capital cost per annum.
The supplier to provide details to confirm ‘Cost of Ownership’ at the tender stage.
Year one warranty claims should be included within the calculation, even if the actual amount is not paid
due to the validity of the warranty against that item.
Cost of Ownership METHODOLOGY

All parts, consumables and labour required to maintain the machine should be recorded during the total
trial duration. The costs should be identified and pro rata for a full year duration. The site should continue
to track this cost for the first 5 years of the machine’s life.
9.8. FAT
Factory Acceptance Testing (FAT): The FAT will take place before the equipment is shipped. Testing will
include, but is not limited to, review of safety compliance (MESS), review of compliance to electrical and
mechanical specifications, review of operator screen / data, review of operator interface, demonstration of
fault recovery from various faults, and demonstration of rates (including maintaining rate during the
changing of a pallet). Individual test runs may last up to an hour to prove capability.
If the equipment is purchased for multiple SKUs, then a minimum of 3 scenarios shall be conducted with
product at either end of the spectrum, together with a more average product. A system shall be able to run
multiple SKUs to test the functionality and rate of the whole module in a real-life scenario.
The supplier should replicate the in-feed on site – i.e., achieve maximum rate at representative spacings.
9.9. Machine Validation Testing

Equipment will be subjected to performance testing to validate its capability against the above KPIs.
During the validation period, the equipment will be operated by PepsiCo trained Operators and the data
should be recorded automatically from the machine’s control panel.
The overall system supplied must be capable to meet all KPI’s simultaneously for the full duration outlined
above. Failure of any individual KPI will render the Site Acceptance Test a failure. All validation timings
will revert to zero and the SAT to be recommenced in whole.
Performance Testing Times & Summary of KPI's
Description KPI FAT Machine Validation
Run full case rates coming
Meets the production Demonstrate rate from packaging without
9.1 Production Rate rates outlined in this capability each scenario backing up into packaging
document at max throughput room over three 8-hr
periods
Demonstrate OIT Trained personnel are able
Operational
9.2 functionality and to operate the machinery
Effectiveness
operability efficiently
24hr/day continuous
Between Service Interval
Operating running between
9.3 or 3 months whichever is
Environment recommended service
greater
intervals
Run across 3 shifts for 5

9.4 System Efficiency Smooth running >95% run continuously
days
Single bag < 0.1% Run across 3 shifts for 5
9.5 System Waste
PP multipack < 1.5% days
Reviewed Every 3 Months

MTBF (mean time
9.6 >30mins during 12 Month Warranty
between failures)
Period
No defected products Run across 3 shifts for 5
9.7 Quality
go out to case packing days
9.8 Changeovers < 30mins < 30mins 10 changeovers
Run across 3 shifts for 5
9.10 Sorting devices <0.01% Miss reading
days
9.10. Start-Up and Fault Recovery

The machine must not require priming at start-up or after recovery from a fault. Following an Emergency
Stop the machine should remember the location of the cases and resume without discharging an incomplete
pallet.
The machine shall have a visible red-light beacon and HMI alarm to alert the operator if the system has a
blockage.
9.11. Maintenance Requirements

Necessary lubrication shall be easy to reach in well-marked lubrication banks.
Equipment will be serviced no more than once every twenty-one days.
Major preventative maintenance should be performed no more than twice per year and should take no
longer than 8 hours.
There should be no mechanical adjustments on the machine unless agreed in advance with the project
team.
Parts should be put together in such a way to leave no room for installation or adjustment error.
10. Site Impact
10.1. Buildings / Access to site

To be reviewed at design phase with site operations management / engineering team.
10.2. Existing Equipment and Operation

The vendor is to integrate the new works in a seamless integration with the existing plant operation.
10.3. Utilities
The Vendor is to declare all utilities requirements as part of the documentation.
The supplier is to clearly indicate in writing in their tender proposal the energy consumption of the new
equipment, including:
• Electricity consumption in kW/hr
• Compressed air consumption in m3/hr
• Any other energy consumption
10.4. Plant Environment

The equipment is to be located in a dry packaging area and is required to operate in a wide variety of
conditions (see below), contamination with oil, salt, and seasoning, with dry machine sanitation i.e. no wash
down.
Temperature -5 to 45 C
Relative Humidity 40 to 99 percent (55% average)
10.5. Noise Control

All production and ancillary equipment shall be designed, constructed and installed to ensure that noise
emissions from the operation of the equipment under normal production operating conditions ( i.e.. with and
without product) both singularly and taking account of the cumulative effect of noise from adjacent
equipment, shall not cause any Production Personnel to be exposed to noise in excess of the first action
level (LEAV, d<85dB(A)) of the Control of Noise at Work Regulations 2005. The Contractor shall provide
information and / or calculations to demonstrate that equipment in his supply complies with this requirement.
Noise measurements made by the Contractor shall conform to BS4196, Part 6, 1981, in so far as a
rectangular parallel piped surface is used for the measurement surface.
For machines operating in proximity with other machines and within a reverberant environment (i.e., within
a hygienic factory) consideration shall be given to the effect of reflected noise, and the cumulative effect of
noise from other nearby machines.
Noise attenuation is required if the peak sound pressure level to which an operator is exposed exceeds
85dB (A weighted)
11. Acceptances and Handover

The vendor will agree at the design stage with the site whether a Pre-Delivery Inspection (PDI) is
appropriate and where necessary set a date for this PDI. It may not be necessary for multiples of the same
equipment to be tested. This should be agreed in advance with the project team.
Prior to shipment, a Factory Acceptance Test (FAT) will be undertaken at the supplier’s premises, details
of which are included within the individual Key Performance Indicator (KPI) documents.
Once on site, a Site Acceptance Test (SAT) will also be undertaken as detailed within the KPI document.
In addition to SAT documentation, the supplier must maintain a detailed “commissioning log” and agree the
Change Management process to be used during on-site working with the site team.

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Operation Dashboard – RFQ & KPI's

Company PepsiCo Foods Vietnam

Site Binh Duong Plant

Project Name Production Dashboard

Revision date 22 September 2023

Date Revision Originator Change Description

04-Aug-2023 A Le Quoc Han First issue

30-Sep-2023 B Nguyen Hoang Vu Clarify more

7. Control System Hardware.................................................................................................................................... 20

1.1. Correspondence & Invoice Address

Position Production Manager Position Engineering & Maintenance Manager

Mobile +84 902470392 Mobile

Email Vu.Nguyenhoang@pepsico.com E-mail tan.luongminh@pepsico.com

All information is to be copied to:

Mobile Mobile + 668 1931 6759

Email Man.PhanMinh@pepsico.com E-mail Varadid.Singsombut@pepsico.com

All Invoices and Paperwork should be sent to:

PepsiCo Foods Vietnam Company. Head Office

PepsiCo Foods Vietnam Company. Binh Duong Plant

1.5. Standards & Specifications

2.2. Project Overview

Figure 1: Examples of a production output dashboard

There are some key performance indicators we want to monitor:

2.3. Program Management

2.4. Works in vendor scope

- LPG: utilize current flowmeters and connect database.

3. System Inputs and Dashboard Requirements

3.1. Production output

Table 1: Example of different PC SKUs

Weight of Bags per Bags per Weight of Weight of Carton

6M 32Gr 10 160 320 5.12

10M 54Gr 10 100 540 4.32

20M 95Gr 10 40 950 3.8

30M 150Gr 5 30 750 4.5

3.2. Line Efficiency

- Actual production is measured as above.

Figure 2: Example of PC line daily TE% in Sep'23

Figure 3: example of PC line machine downtime waterfall in Sep'23

3.3. Material Efficiency

Raw material Potato Pellet Powder

VO (vegetable oil) VO (vegetable oil) VO (vegetable oil)

SSN (seasoning) SSN (seasoning) SSN (seasoning)

Film Film Film

Pack material PP bag PP bag PP bag

Carton LDPE poly bag LDPE poly bag

3.4. Utility consumption

Figure 4: Example of current water usage tracking

4.1. Site Access and Conditions

4.3. Post Project Support

4.5. Manuals and Documentation

Cost of ownership, first 3 years. Adobe .pdf ✓

4.6. Project Stage Gate Definitions

5.1. Construction Standards

5.2. MES (SCADA) Software

5.3. PLC Software (Version issue）

5.6. Tagging and Identification

5.7. Systems Interfaces (I/O and Ethernet TCP/IP）

6. Requirements for Communication to the External Information System – MES

Centrelines (tags in PLC code, sent to SCADA)

7. Control System Hardware

7.1. Proposed Network

7.2. Control Panels

7.3. Field Equipment