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.
2.
3.
4.
5.
6.

Project Objectives
Deliverables
Milestones
Technical Requirements
Limits & exclusions
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.

Relative or Numerical Scale

Project Objective
Cost
Time

Scope

Quality

1
Very Low
Insignificant Cost
Increase
Insignificant time
increase

Scope decreases
barely noticeable

Quality degradation
barely noticeable

2
Low
<5% cost increase
2 days increased

Minor areas of
scope affected
Only very
demanding
applications are
affected

3
Moderate
5-10% cost
increase
2-5 days
increased

4
High
10-15% cost
increase
5-10 days
increased

5
Very High
>20% cost
increase
>10 days
increased

Major areas of
scope affected

Scope reduction Project end item

unacceptable to is effectively
sponsor
useless

Quality reduction Quality reduction Project end item

requires sponsor unacceptable to is effectively
approval
sponsor
useless

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

Project Objectives

Very High
Probability
High
Probability
Moderate
Probability
Low
Probability
Very Low
Probability
Probability
Impact

T-C

T-A

T-B/C-A

S-A

Q-A

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

Activity
Rotory
Brake Unit
Base Cam
Transmission Body
Bell Nozzle Cylinder
Base Mold Support
Stretching Cylinder
Transfer Arm Assembly
Oven Section Hydraulic
Console Assembly
Compensation Valves
Preblow Valves
Mold Locking
Star
Lift Cylinder
Lever
Rinser
Valve Maintenance
Capper
Support of Tulip
Electrical
Mechanical Operations
Level Probe
Vacuum Drum
Hose Pipe
Infeed Worm
Glue Roller
Main Block
Vacuum Drum 1
Centering Turret
Cutter Assembly
Vacuum Distribution
Glue Roller 1
Heater
Applicator
Brake Unit 1
Guide
Air Conveyor
Blower
FRL Unit
Head Assembly
Article Conveyor

Activity
time

Predecessor 1
3
2
2
2
2
2
1
2
2
1
2
2
2
2
2
1
2
2
2
2
2
3
2
5
8
9
6
2
6
3
6
2
5
5
2
3
4
6
4
2
5
6

Rotory
Brake unit
Base Cam
Transmission Body
Bell Nozzle Cylinder
Base Mold Support
Stretching Cylinder
Transfer Arm Assembly
Oven Section Hydraulic
Console Assembly
Compensation Valves
Preblow Valves

Lift Cylinder
Lever
Rinser
Valve Maintenance
Capper
Support of Tulip
Electrical
Mechanical Operations
Level Probe
Vacuum Drum
Hose Pipe
Infeed Worm
Glue Roller
Main Block
Vacuum Drum
Main Block
Cutter Assembly
Vacuum Distribution
Glue Roller
Heater
Applicator
Brake Unit
Guide
Air Conveyor
Blower
FRL Unit
Head Assembly

Predecessor 2

Predecessor 3

Brake Unit
Brake Unit
Base Cam
Base Cam

Brake Unit

Console Assembly
Brake Unit

Star
Lift Cylinder
Rinser
Capper
Support of Tulip
Electrical
Level Probe
Vacuum Drum
Hose Pipe

Hose Pipe
Vacuum Drum

Cutter Assembly

Mold Locking

Lever
Lift Cylinder
Rinser

Level Probe

Electrical

Warmer Conveyor
Conveyor Bend
Warmer Comb
SU System
Dry Run
Quality Results

3
4
3
4
1
2

Article Conveyor
Warmer Conveyor
Conveyor Bend
Warmer Comb
Warmer Comb
Dry Run

Glue Roller 1

Table 3. Activity Description of Project

Brake Unit 1

Figure 1. Gantt Chart Of various Activities Of Project

Figure 2. CPM Diagram

Project Team
MACHINES
Blow Molder

Raj KumarSarvan Lal Bahadur

MahendarPuranvasi S.Rawat Hemant
Lalit

1.1 Rotory
1.2 Brake Unit
1.3 Base Cams
1.4 Transmission Body
1.5 Bell Nozzle Cylinder
1.6 Base Mould Support
1.7 Stretching Cylinder
1.8Transfer Arm Assembly
1.9Oven Section Hydraulic
1.10Console Assembly
1.11 Compensation Valves
1.12Preblow Valve Air Leakage
1.13Mold Locking assembly

R
S
R
R
S
R
R
S
R
S
S
S
R

S
S
R
S
R
R
S
S
R
S
R
S
R

S
R
S
R
S
S
S
S
S
R
S
S
S

PradeepSanjayArvind R. Tiwari Sri NarayanProdu. Officer

Shift Engg.Quality Officer

S
S
S
S
R
S
S
R
S
R
S
R
S

2. FILLER
2.1Star
2.2Lift Cylinder
2.3Lever
2.4Rinser
2.5Valve Maintenance
2.6Capper
2.7Support Of Tulip
2.8Electrical
2.9Mechanical Operation
2.10Level Probe

R
S
R
R
S
S
R
R
S
R

S
R
S
R
R
R
R
S
R
S

3. LABLER
3.1Vacuum Drum
3.2Hose Pipe
3.3Infeed Worm Assembly
3.4Glue Roller assembly
3.5Main Block
3.6Vacuum Drum Assembly
3.7Centering Turret Guide Assembly
3.8Cutter assembly
3.9Vacuum Distribution
3.10Glue Roller Assembly
3.11Heaters
3.12Applicator

R
R
S
R
S
S
R
R
S
S
S
S

R
S
S
S
R
R
R
S
S
R
S
R

S
S
R
S
R
R
S
S
R
S
R
R

4. UNSCRAMBLER
4.1Brake Unit
4.2Guide (2lt)
4.3Air Conveyor
4.4Blower
4.5Frl Unit Air Leakage

R
S
R
R
R

S
R
S
S
S

5. CASER
5.1 Head Assembly
5.2Article Conveyor

R
S

S
R

6.WARMER & CONVEYORS

6.1Warmer Conveyor
6.2Su System

R
S

S
R

R
S

7.DRY RUN
7.1Blow Molder Trial Run
7.2Filler Trial Run
7.3Labler Trial Run
7.4Unscrambler Trial Run
7.5Caser Trail Run

R
R
S
R
S

S
S
R
S
R
R

8.QUALITY RESULT

Table 4. Responsibility Matrix Of Project

MACHINES
1. DISASSEMBLING
2. MAINTENANCE OF MACHINES
2.1 BLOW MODLER

2.1.1 Rotory
2.1.2 Brake Unit
2.1.3 Base Cams
2.1.4 Transmission Body
2.1.5 Bell Nozzle Cylinder
2.1.6 Base Mould Support
2.1.7 Stretching Cylinder
2.1.8Transfer Arm Assembly
2.1.9Oven Section Hydraulic
2.1.10Console Assembly
2.1.11 Compensation Valves
2.1.12Preblow Valve Air Leakage
2.1.13Mold Locking assembly
2.2 FILLER

2.2.1Star
2.2.2Lift Cylinder
2.2.3Lever
2.2.4Rinser
2.2.5Valve Maintenance
2.2.6Capper
2.2.7Support Of Tulip
2.2.8Electrical
2.2.9Mechanical Operation
2.2.10Level Probe

DAYS COST
8
400000 TOTAL COST
6350000
47
5500000
1500000
200000
150000
150000
200000
300000
200000
100000
100000
40000
15000
20000
12000
13000
1000000
200000
150000
100000
40000
30000
30000
350000
30000
20000
50000

2.3.1Vacuum Drum
2.3.2Hose Pipe
2.3.3Infeed Worm Assembly
2.3.4Glue Roller assembly
2.3.5Main Block
2.3.6Vacuum Drum Assembly
2.3.7Centering Turret Guide Assembly
2.3.8Cutter assembly
2.3.9Vacuum Distribution
2.3.10Glue Roller Assembly
2.3.11Heaters
2.3.12Applicator

700000
15000
1700
40000
30000
50000
100000
120000
18000
200000
20000
19000
86300

2.4. UNSCRAMBLER

400000

2.3 LABLER

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

120000
40000
50000
150000
40000

2.5. CASER

600000
400000
200000

2.5.1 Head Assembly

2.5.2Article Conveyor

1300000
800000
500000

2.6.WARMER & CONVEYORS

2.6.1Warmer Conveyor
2.6.2Su System
3. ASSEMBLING

400000

4.DRY RUN

50000
12000
7000
5500
22000
3500

4.1Blow Molder Trial Run

4.2Filler Trial Run
4.3Labler Trial Run
4.4Unscrambler Trial Run
4.5Caser Trail Run
5.QUALITY RESULT

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.