INTRODUCTION
Section one: Introduction Story of success
The soft drink Pepsi-cola was created by a pharmacist, caleb bradham,who gave his tonic its name (from Greek Pepsis," digestion")in 1898 and incorporated the pepsi cola Co. in 1902.After two bankruptcies and several rain corporations, the Pepsi-cola trademark and assets were bought in 1931 by Charles G.Guth ,who improved the formula and marketed a 12-ounce bottle for f or five cents with huge success. Pepsi-Cola merged with soda-fountain chain loft,inc.,in 1941,and in 1965 it merged with Frito-Lay,Inc.,adoping Frito-Lay,Inc.,adoping its current name, PepsiCo Inc.In the 1970's &80's PepsiCo bought restaurant chains such as Pizza Hut, t aco Bell, and Kentucky Fried Chicken, but in 1997 it spun off its restaurant business into a separate company, Rincon Global Restaurants. In 2001 Quaker Oats Co. merged with PepsiCo.
PEPSICO INC. as an Automated factory :
Pepsico Inc. is a global enterprise established over a hundred years ago in the United States. After a series of successes and hard times, it spread into a number of countries, of which is Jordan. Pepsico Inc. in Jordan uses the highest quality services and machinery aimed to provide many products with high efficiency and quality.
PepsiCo, Inc. is one of the world's top company product companies with many of the world's most important and valuable trademarks. Its Pepsi-Cola Company division is the second largest soft drink business in the world, with a 21 percent share of the carbonated soft drink market worldwide and 29 percent in the United States. Three of its brands--Pepsi-Cola, Mountain Dew, and 1
Diet Pepsi among the top ten soft drinks in the U.S. market.
PEPSICO JORDAN:
At the beginning the factory was basically depend on the glass bottles line For that the only drinks were to produce are Pepsi, Miranda and Seven-Up with two sizes of bottles the liter and the 250 ml. The machines in this production line were almost controlled manually and the human source was mainly needed.
After a while the line of the cans has been added, and it has a huge success at the market for its effective and can be recycled for other industries. At this time the main size of cans was 250 ml with a suitable price for it, and to ensure more effectiveness another size has been added which is the 300 ml. This new production line was more modern and the human source began to be reduced for the machines became more automated and more productive, and at that time the revolution applications of electrical field was in its height. By time and after a long way of success the factory began to revolute with pace. The plastic was used in producing bottles sizes 2.25 litre, 1 liter, and 0.5 liter beside glass; also it becomes more widely used. Also other products were added to list of the factory's productions such as Mountain Dew and Aquafina water.
Here in this report we will talk about the plastic plastic production line because because It has a modern machines . This machines are from KRONES PRESSANT company . it is a German company company that is one of the world leaders in solutions for production lines ,packaging liquid and foods.
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COMPANY PROFILE
Corporate Profile
PepsiCo is a world leader in convenient snacks, foods, and beverages, with revenues of $60 billion and over 285,000 employees. PepsiCo owns some of the world's most popular brands, including Pepsi-Cola, Mountain Dew, Diet Pepsi, Lay's, Doritos, Tropicana, Gatorade, and Quaker. Our brands are available worldwide through a variety of go-to-market systems, including direct store delivery (DSD), broker-warehouse, and food service and vending. PepsiCo was founded in 1965 through the merger of Pepsi-Cola and Frito-Lay. Tropicana was acquired in 1998 and PepsiCo merged with the Quaker Oats Company, including Gatorade, in 2001. Divisions
We report our operations results as follows, by six segments:
PepsiCo Americas Beverages (PAB)
Frito-Lay North America (FLNA)
Quaker Foods North America (QFNA)
Latin America Foods (LAF)
Europe
Asia, Middle East & Africa
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Section two Description of the production line: (Plastic Bottles):
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This production line produces PEPSI, MERINDA, 7-UP sizes 0.5L, 1L and 2.25L The whole process can be summarized as follows:
•
Manufacturing of the empty bottles
•
Labeling & coding the Process
•
Filtration of produced empty bottles Process
•
Filling & capping the bottles
•
Packaging
1. Manufacturing of the empty bottles:
The bottle comes from the manufacturer in KSA as in the figure. And by some automated process it will be like the one we see in supermarkets!!
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This process has many steps: Step 1 : Preform (Small Plastic Bottle) Feeder : •
Function :
The preform feeder provides a continuous supply of performs (small plastic bottles) to the machine.
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Operation : The generator produces current at high voltage (7000 V). The anti- static bars create an electrical field. The molecules in the air transform into positive and negative ions. Contaminants, perform bottles are charged with static electricity thereby attracting the ions produced and the static electricity load is cancelled out. The antistatic bars in the pre-form ionizer are linked to laminar airflow generator units which create a flow of ionized air. The airwaves increase the efficiency of the ionization treatment while also dedusting the pre-forms.
Step 3 : The bottles are heat conditioned :
•
Function:
The heating modules ensure controlled heating inside the bodies of the pre-forms so that they can be blown after transfer to the molds. When the machine is started, the pre-forms will begin feeding only once the oven has reached the production temperature (as defined in the production set up).The temperature sensor
informs the
PLC which starts feeding.
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Step 4 : The bottles are blown in the mold (BLOWING STATION) :
•
Function:
The blowing station transforms the pre-forms bottles into the blown finished items. Mold support unit
Here, the operation is done at 40 bar to make the heated bottles in the blown finished form either 0.5,1, or 2.25 liters.
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2. Labeling & coding the bottles :
(sensors used)
In this step, the bottles are labeled .After labeling the bottles a color sensor is used to check that there is a label on the bottle .But if it is not labeled , the rejecter will throw the bottle out of the line . After that, a laser printer is used to print a code (product number) and date on the bottle.
The laser printer
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3. Filtration Process:
After labeling and coding the bottles we are to ensure that the bottles are well cleaned, and this process is just before the liquid filling and the capping process.
For filtering, the Pepsi factory uses a machine that sanitizes every bottle by a Special liquid 'gas' and under certain temperature, and this will most of the microbes.
This process is so important and as a result of it a factory will get the consumer's goodwell, as well as the peace of mind. 4. Filling & capping the bottles:
In this step, the bottles are filled automatically with the desired liquid. The machine is using the level fill technology (using level detector) to fill the water .After filling the liquid, the bottles will capped . At the end of this step the liquid level in the bottles will checked by a photo-electric sensor (will mentioned in next section) . If the level is not correct ,a rejecter that will push any undesired bottles off the line.
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5. Packaging:
In this step, the bottles will be arranged in rows. Every six bottles will enter the oven to be packaged .In this stage, there are many sensors used for controlling the conveyer belt speed when the line is full. This package is now ready to sale it.
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Section three: Measurement systems and transducers used:
There are many measurement systems in the production line. In this section we will talk about their function and some important characteristics. Data sheets will be at the appendix A
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Sensors used in Manufacturing of the empty bottles Process:
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Photo-electric sensor:
Function:
This sensor is used for detection of the overflow of pre-forms number going to the elevator column, it is normally closed and if the number of pre-forms exceeded a predetermined amount it will stop the conveyor then start it again when elevator column is empty.
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Sensors used in Labeling & Coding Process :
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Optical laser Distance sensor
Function:
This sensor is used to control the rotational speed of the labeling roll as shown in the figure. This sensor determines this speed by sensing the distance between the sensor the roll edge and because we know previously the roll diameter a controller will increase the speed every time the diameter decreases.
Capacitive proximity sensor
•
Function:
This sensor has been installed under the label roll and it gives a signal when the roll diameter is enough to label the bottles, but when the sensor detects no labeling roll the PLC will immediately converts the work to the other roll.
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Color Sensor: 13
Function:
This sensor has been installed in the assembly line after the labeling machine in order to distinguish between the bottle which have labels put on them and which are not. The sensor used is used for detection of the white color (on the top of the label on the bottle) .This sensor is connected to an actuator (rejecter) that will push any unlabeled bottles off the line. So only the labeled bottle will pass to the next step.
Product features canning
60 mm
olerance:
± 9 mm
canning range:
250 ... 1.000 mm
easuring
onto reflector PL 80 A
ight source:
LED
ype of light:
red, blue, green
ave length:
470 nm, 525 nm, 640 nm
ight spot size:
13 x 13 mm (at 60 mm)
Technical data Dimensions (W x Hx djustment: Supply voltage min ... max:
30 4 x 53 x 80 mm Teach-in DC 10 ... 30 V
ipple:
< 5 Vss
ower
< 80 mA
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Sensors used in Filling and capping process:
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Photo-electric sensor: Function :
These sensor is used for detection of the liquid level in the bottle after filling process . It is used to remove the undesired bottle before going to the labeling process. It is connected to an actuator (rejecter) that will push any undesired bottles off the line.
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Some characteristics : Type of transmission: Infrared (transmission frequency = 1450nm). Nominal sensing distance: 50m (use between 10cm and 20cm). Rated supply voltage: 10.8-26.4 volts, with the protection against reverse polarity. Degree of protection: IP 65. For the solid protection the object is entirely protected against dust, and has a complete protection against contact. For the liquid protection the sensor is protected against water jets, so water projected by a nozzle against enclosure from any direction shall have no harmful effect. Maximum switching frequency: 1 Khz
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Sensors used in Packaging process:
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Inductive proximity sensor
Function :
Inductive proximity sensors are devices that detect the presence of a metal object without physical contact; instead it uses an electromagnetic field to detect metal targets. Inductive proximity sensors are often shielded to improve sensor output. The inductive proximity sensor has been utilized in Pepsi assembly line to give an indication about the busyness of the assembly line. This has been done by installing two metal plates at both sides of the assembly line, so when bottles pass they will push this metal plate bringing it close enough to the proximity sensor to initiate an electromagnetic field and thus knowing that the line is busy. Then after knowing that the line is busy the controller can take the
decision of slowing the conveyer motor to give other parts of the assembly line enough time to process the bottles.
Product features ax.
sensing
12 mm 16
nstallation
in
Non-flush
utput function:
Complementary
witching
2,000 Hz
onnection type:
Connector M12, 4-pin, gold-
witching
PNP
Technical data esign:
Cylinder with thread
hread size:
M18 x 1
upply voltage:
DC 10 ... 30 V
ipple:
<= 10 %
ower
<= 15 mA
ontinuous
<= 200 mA
Hysteresis ... max
min
e roducibilit : Temperature drift (of sr): MC:
1 % ... 20 % (Ub and Ta constant), 5 % of sr (Ub and Ta constant) 10 % according to EN 60947-5-2
Short-circuit protection Reverse polarity protection: Power-up pulse suppression: nclosure
IP68, IP 69K
Ambient temperature min ightening
Time before
-40 °C ... +80 °C, +100 °C for 15 minutes 50 Nm
delay
50 ms
ousing
Stainless steel V4A 1.4404,
oltage drop:
<= 2 V at Ia max 17
Optical reflex sensors :
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Function :
These sensor is widely used in the assembly line .these sensor is connected to the PLC which has as internal software real timer . When the timer overflows , PLC send a signal so the conveyor belt will slow down its speed . But if a signal from the sensor is sent to the PLC , the timer will reset so no change in the conveyor belt speed .
It has many different applications as follows: 1- Changing the speed of the conveyor belt : These application is existing in the following places : After typing the date and code on the bottle. •
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After the package of the six bottles are moved from the oven.
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At two meter distance from the end of the production line :
In this place the sensor has different function which is opposite to the above one .( It is connected to other timer in the PLC ). if the packaged bottles aren't taken out from the conveyer , the line will be busy . A continuous signal will be send to the plc to slow the speed of the conveyor belt .
Note( this sensor has a priority over the first two OPTICAL REFLEX sensors ) Arranging the bottles in rows before entering the packaging oven : •
This reflex sensor is installed in the region where all the bottles get placed in rows, and in each row there is a metal plate that hangs on the roof of the machine. If bottles are placed properly in rows (with no bottles missing in any row) then they will push this metal upward and hence no signal will be sent. But when a bottle is missing for example this metal plate will hang down and sensor will send a signal to pass a bottle in this row .
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Safety Sensors : 18
These sensors are used to protect the workers from different hazards that are in the working area. In the Pepsi factory they are used to turn off the machines when a worker approach a dangerous place, such as the automatic hydraulic fork lifter which is used to move large packages off the assembly after the wrapping machines wraps the whole package with nylon.
RESEARCH METHODOLOGY
Pepsi – An Introduction Introduction
PepsiCo, Inc., major producer of carbonated soft drinks, other beverages, and snack foods. Its beverage division, Pepsi-Cola Company, bottles and markets several popular brands of soft drinks in the United States and throughout the world. PepsiCo also owns Frito-Lay Company, the leading snack-food maker in the United States. PepsiCo is based in Purchase, New York. PepsiCo’s soft drink products include Pepsi, Diet Pepsi, and Mountain Dew. Other beverages include Lipton Brisk and Lipton’s Brew iced teas, All Sport athletic drink, and Aquafina bottled water. Frito-Lay products include Lay’s and Ruffles
Potato Chips, Fritos and Doritos Corn Chips, Chee-tos Cheese Snacks, Tostitos Tortilla Chips, Rold Gold Pretzels, and Grandma’s Cookies.
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Objective of the study
To understand the production procedure of the Pepsi co. To know the quality management of the Pepsi. To know the manufacturing unit of the Pepsi co. To know about the technology used in MNC’s like Pepsi co.
SWOT Analysis 1- Strength
Activities the firm does well or resources it controls are called strength. Resources that a company contains, size of organization, size of market, loyalty of the organization’s products, sales point of product of t he company shows the company
strength. The strength of PEPSI lies in the loyalty of the product, their market share, size of market, having numerous sales points and efficient delivery system. 2- Weaknesses
Activities the firm does not do well or resources it needs but does not possess. Such activities that a firm does not perform or not have some resources those other competitors have. Locally, PEPSI is enjoying its position in the market. Internationally, PEPSI faces some tough competition from Coca-Cola. Their weakness is the lack of relationship marketing in some parts of the world. And also in Pakistan they are facing some serious problems in building the relationship with institutional customers. 3- Opportunities A combination of favorable circumstances or situations for organization’s product/s
such as loyalty of customer about your products, social environment, size of target market, size of organization, advantages over other competitors etc. Opportunities are coming in the market day by day in the shape of new retailers. PEPSI has a big research department; they try to capture each new retailer who comes in the market. Pakistan population size is rapidly increasing with the passage of time so opportunities are there for Pepsi to enhance its sales volume more than others. 4- Threats
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Unfavorable circumstances that a company faces time by time to achieve its goals are called threats. Some times small companies introduce the same products with low quality and low price that the company did not produce. Locally, PEPSI stands second to none. Internationally, Pepsi is facing heavy competition from its rival Coca-Cola. Coca-Cola is focusing global market while PEPSI is somehow lagging behind. The situation can become a serious threat to PEPSI globally.
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ANNEXTURE Analysis: Q1. Do you manufacture more then one product on same machine?
Yes
No
Inferences
1. 65 % of machinories are used for more then one product manufacturing. 2. Only 35 % of machinories are used for only one product.
Q.2While manufacturing what is the priority of the company?
Price 22
Product feature
Brand
Service
Durability
Inference
1. 30% of company gives importance to price. So it shows that Indian company are very price sensitive. They give more importance to price over the brand. 2. 26% give importance to brand. So price and Brand matter a lots for the costumers. And they are also want best brand in best price. 3. 19% to product feature Service 16% and durability 9% Service is also a big factor for the company they are less interested in the durability.
Q3. Where you prefer to suply manufactured product.
Exhibitions
Co.shoppee
Showroom 23
Inference:
1. A majority of companys prefer to buy from showrooms. Very less proposition of companys buys from Exhibitions. 2. 47% companys are prefer to by from the showrooms because the showrooms are more convenient to companys they also think that these shops give more discounts. 3. People are less interested to buy from the exhibition they only visit the exhibition for price quotation of the product and the comparison of the product.
Q.4.You prefer to buy from the same as you have mentioned in Q.3 because of following reasons
Attractive Price
Service
Demonstrations
Offers
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Inference
1. Companys buy from
showrooms because of
the
service and
convenience. These are two main factors. 2. Companys are preferred to buy from the showroom because of they think that these convenient store may provide good after sell service. 3. Company also thinks that there is more chance to bargain and they can get more discounts in these showrooms. 4. Price also a factor that attract the company in these showrooms.
Q.5. How frequently you change your machines durables?
1-3 years
3-5 years
5-10 years
More than 10 years
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INFERENCE
1. 54% Companys prefer to change company durables within 5-10 years. In India people do not change company durable frequently. 2. 23% companys do not change their company durable within 10 year. 3. It represent that Indian company do not prefer to change their company durable frequently.
Conclusion
Calibration is the process of establishing the relationship between a measuring device and the units of measure. This is done by comparing a device or the output of an instrument to a standard having known measurement characteristics. Calibration of the above measurement systems used in this production line is depending on the quality of the product compared with the standards used for the product .So, the factory does not calibrate the systems at a specified time. Calibration is done by sending the sensors to the company (here SICK company) to calibrate them using a calibration devices. 26
By visiting the factory and the production line, we see that every thing must be arranged to avoid any mistakes. Safety of the worker there is the most important thing. All the processes are automated and connected to the PLC unit by the measurement systems. Some sensors are same but they used in different function in the production line. Finally, any problem in any measurement system will make the production line to stop. So, they always check their output to see if they need any maintenance.
References :
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Leuze electric website www.leuze .com
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Operating manual of the manufacturing the bottles.
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Sick company website www.sickusa.com
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Pepsi website www.pepsico.com
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Data sheets in the appendix for the sensors characteristics.
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