Professional Documents
Culture Documents
of TPM Success
Headline
stories
in
Food Business
Headline
Market Share
>60%
<60%, >30%
<30%
No Presence
PepsiCo Business
Headline
Food & Beverage Revenues, $ Million
Nestl
PepsiCo
Unilever
Kraft Foods
Coca-Cola
Groupe Danone
0
20,000
40,000
60,000
80,000
100,000 120,000
PepsiCo- In India
PepsiCo
Headline
PepsiCo America
Foods
PepsiCo International
EUROPE
PepsiCo International
AMEA(Asia Middle East Africa) Division
PI
INDIA REGION
PI
INDIA BU FOODS
PepsiCo America
Beverages
PepsiCo International
PI
CHINA REGION
PI
ASIA PACIFIC
PI
INDIA BU BEVERAGES
PI
Other Regions
PepsiCo India
Foods is a part of PI-AMEA
Headline
(Asia, Middle East & Africa) and one of the
fastest growing businesses for PepsiCo.
.Lays and Kurkure are 2 among the top 3
Channo
Faridabad
across India
.8 Contract manufacturing sites
Approximately 1350 direct employees and
10000 associates including farmers, vendors
and sales agents are part of the company.
Rajkot
Kolkata
Pune
Hydrabad
Banglore
Hosur
Erode
Headline
Potato Chips
Carbonated Drink
Fruit Juices
Energy Drink
Health Food
Headline
TPM
Kick-off
in
Channo
Plant
Consistent commitment in
TPM Award
Health Check audit
scheduled in Kolkata &
Channo Plant
TPM Excellence award in
Pune Plant
TPM
Excellence
Award
Kolkata Plant
TPM
Excellence
Award
Channo
Plant
TPM
Excellence
Award
Pre audit
Cleared Pune
Plant
2011
2010
2009
2008
2004
Our Vision
Headline
Headline
Sustained growth
Empowered People
Empowered Employee
Pillar Responsible
FI
JH
PM
ET
QM SHE
DM
OPTM
Background
From June,2010 on words 59% of operatives has joined in
Headline
Kolkata plant family, It was the Challenge to us forTo acclimatize new Operatives in our PepsiCo Culture
Cultural integrity between Old & New Operatives
Build a wining team by improving Equipment competency & multi skilling
Plant Capacity
2011
25 Times
288*
2010
16 Times
11.6 Times
2009
182
8 Times 2007
1 2004
Basic Process
Headline
Fail
Mandatory Class
room Induction
Assessment
Pass
Fail
Placement on Basic
Job under
supervision
Written Assessment
Pass
Handling individual
process
(Skill Level 2)
Joining
Challenges
Scaling up production wrt.
market demand
Taking new operatives
competency level upto the level
of old one with out hampering
the normal production / Overtime
Opportunity
Equipment , Process competent
& Multiskill Old operators
Sufficient knowledge bank
generated During TPM Journey
We Identified
Skill Level 3 & 4 Operative to coach the New
Headline
operative on lines.
Prepared Pairs of
Guide & Learners
Both in same shift
G
L
Old operative
(Guide)
New operative
(Learner)
Self Learning
On Job
Coaching by
Guide
Coaching by
Line Supervisor
Headline
Pre
Test
Evalua
tion
All
Operatives
who has
joined after
1st June
2010
Selecti
on of
LEAR
NER
Primary
responsibility
lies with the
learner to
learn more on
topics covered
during pre test
Selecti
on of
GUIDE
Based on
Voluntary
nomination /
Decided by
Functional
heads
Progress
monitoring
by circle
facilitators &
Each 1
Teach1 Core
Team
On
the
Job
Trainin
g
Guide will help
learner to
develop
functional skill
with know why
on station
specific area s &
Other topics
Excellent>85% on
overall marking
Post
test
Evalua
tion
Evaluation of
guides
performance to
be on the basis
of the learners
performance in
post test
Evaluation
May be a
criteria for
probation &
Confirmation
Reward &
Recognition
May be a
criteria for
Selection in
Shop floor
academy
Headline
Minimum 5 OPLs
& 2 Kaizens
during learning process
Learner should be able to do
the following job individually
OPL Preparation
65
Kaizen filling
60
Fuguai identification
55
50
75
54
Pre test
Target
Pre test
Process parameters
JH of Equipment
Circle activities
PM & Boil out activities
Machine settings
General inspection of equipment
PPA / Know why
Process parameters
Defect troubleshooting
Target
On job Safety
Efficiencies / Waste
Quality parameters
75
70
65
Guides
60
55
70
59
50
Pre test
Target
Pre test
Target
General TPM
Work Station safety
Food safety
HACCP
Why- Why Analysis
Kaizen / OPL
SOPs / WIs/ Shop floor Discipline
Employee welfare
Headline
Safety Manual
JH Manual
JH for operators
OEM manuals
Why Why Sheets
Headline
Learners & Guides are using On Line
learning Center for Skill enhancement
16
2011YTD
354
100
200
300
400
63
2011YTD
965
500
1000
1500
Headline
75
70
65
76
75
Post test
Target
G
o
o
d
60
55
54
50
Pre test
Pre test
Post test
Target
% Marks in Evaluation
% Marks in Evaluation
80
65
60
55
70
70
Post test
Target
59
50
Pre test
G
o
o
d
236 Kaizens
recieved in a
Month
783 OPLs
in a
Month
Line 1
Grader to
Destoner
Line 2
Headline
Line 3
Blender
Line 4
Blender
Trim n Pare,
Slicer & Fryer
Extruder
Extruder
Extruder ,
Over & Fryer
Optics &
Seasoning
Fryer &
Seasoning
Fryer &
Seasoning
Seasoning
Packing
machine
Packing
machine
Packing
machine
Packing
machine
QC Checking
QC Checking
QC Checking
QC Checking
Taping
Machine
Taping
Machine
Taping
Machine
Taping
Machine
Line 5
Grader
Serpentine
washer
Trim n Pare,
Slicer & Fryer
Optics &
Seasoning
Packing
machine
QC Checking
Taping Machine
M/S Operatives
FG store
New Operatives
Plan
Actual
Jun-11
May-11
Apr-11
Mar-11
Feb-11
Jan-11
Dec-10
Nov-10
Oct-10
Sep-10
Aug-10
Jul-10
Jun-10
May-10
Apr-10
Mar-10
Feb-10
Jan-10
Headline
Headline
Top10 Learners
Appreciation
for
all
>85%
Scorer
Top 10 Guides
Best 3 Guides
Appreciation of Guides whos
Learner achieved >75% Marks
Headline
Discussion of the results with all Learners &
Guides who has not achieved pass marking.
7 Sep, 2011
10 Oct,2011
Oct, 2011
Oct, 2011
Headline
Usage of Potato
Headline
Raw Material
Process
Agro Department works
for production & storage
of potatoes
Finish Product
Headline
Pune Plant Potato Requirement
2011
Projection
2010
2009
2008
2007
2006
2005
2004
MT
2011 Projection
2010
2009
2008
2007
2006
2005
2004
MT
Headline
In India only 5 % of potatoes are suitable for Chips processing
Hence we adopted contract farming model to produce Chip Grade Potatoes
for our production
Rain Fall
Headline
Humidity
Temp.
Pepsico
Before
2005
PepsiCo
Local
Players &
Local
Players
MNC
Competitors
2006 to
2009
After
2009
New Field
Fertile fields
Barren Land
Existing
Newly proposed area
Confident Farmers
Challenges Evaluation
Area
Land
Headline
Challenge
Idea
Level of challenge
Low
Waste land
High
High
High
Water
Mind blokage
High
Training about potato farming
Farmer
Money
Technology
Med
Win win model for contract
farming
High
High
Med
Med
High
Segregation of
medium stones
Old land
Leveling of field
Headline
Flood irrigation
Sprinkler irrigation
Drip irrigation
3393966
2129188.8
1774324
No
Yes
Yes
Huge
Medium
Less
No
No
Yes
Average
Average
Max
Cost investment
Less investment
Expensive
Operational ease
Max
Less
Less
Max
Average
Less
Diesese risk
Headline
Headline
In Early stage
Crop Development
Helping to farmers
Headline
We are helping
farmers financially
For drip irrigation
41%
Govt subsidy
Pepsico
Farmer
We are facilitating
farmers to get Govt.
subsidy
For drip irrigation
Pilot Project
Headline
Normal
field crop
Barren
land Crop
5.2
4.9
Growth Crack
3%
2%
Multiplication ratio
6.5
KPIs
Result
Satisfactory
Good
Satisfactory
Drip Irrigation
270
1000
900
814
250
800
200
600
150
120
400
100
50
286
200
10
0
2009
2010
Acres
2011
2009
2010
Acres
2011
Support to farmers
Farmer support
Headline
Financial
Technical
Technical know
Direct support
Drip irrigation
Output quality
incentive
Subsidized
chemical kits
Facilitation
Bank Loans
Fertilizer
availability
Crop
Insurance
Soil Sampling
Procuring
equipments
how training on
agronomical
practices
Awareness about
crop protection
Technical visits
Expert advocacy
Rabi 75%
Jan - Mar
Nagrota
Punjab
Channo
NEW DELHI
Meerut
Pune
Ujiain
KOLKATA
Indore
Pune
Belguam
CHANNO
KOLKATA
(1800 Kms)
(4 Days)
Chennai
Bangalore
Hassan Kolar
Kharrif 25%
Aug - Nov
Pressure
damage
Rottage
Rottage potato
Transit loss
12
10
Rs. 76 Lakh
2
0
2007
2010
2007
2010
Analysis
Why Potato gets rottage
Headline
Damage of potato
Pressure damage on
bottom layer & body
sides
Rubbing / Extra
pressure
Suffocation of potato
No air circulation
facility
Design constraint
Improvement
Reduced Pressure damage by providing padding
on trucks forHeadline
potato transportation
No Padding
Straw jute
Padding
Before
After
Improvement
Headline
Karakuri
Provided air pipe which takes fresh air from
Atmosphere when truck moves and gives fresh air
Air to sack stored in the truck
Result
Headline
Saving
81 Lakhs
12.00%
10.00%
8.00%
6.00%
4.00%
2.00%
0.00%
2007
2007
Actual 2010
Actual 2010
Target 2010
Target 2010
Headline