Nestle Water, Pakistan

TECHNICAL STORE AND
SPARE PARTS ANALYSIS

NESTL WATERS, ISLAMABAD
UMAIR ZAHID
2014
GHULAM ISHAQ KHAN INSTITUTE OF ENGINEERING SCIENCES
&
TECHNOLOGY
Contents
1.
ABSTRACT ............................................................................................................................................... 1
2.
TECHNICAL STORE OVERVIEW...................................................................................................... 2
3.
ERSA ITEMS ............................................................................................................................................ 3

3.1 OVER STOCKED ITEMS .................................................................................................................... 5
3.2 UNDER STOCKED ITEMS ................................................................................................................ 6
3.3 ITEMS THAT HAVE REACHED REORDER POINT .................................................................. 7
3.4 NON-MOVING ITEMS ........................................................................................................................ 8
4.
UNBW ITEMS ......................................................................................................................................... 9
5.
SPARE PARTS ....................................................................................................................................... 11
6.
DETAILED LIST OF SPARE PARTS ACCORDING TO MACHINES ...................................... 12
6.1 GENERATORS ......................................................................................................................................... 13

6.1.1 CATERPILLAR 365KVA GENERATOR................................................................................... 13
Function in Factory ............................................................................................................................ 13
Spare Parts and their Availability in Technical Store ........................................................... 13
6.1.2 CUMMINS 50KVA GENERATOR .............................................................................................. 13
Model ....................................................................................................................................................... 13
6.2 TECHLONG SYSTEMS .......................................................................................................................... 14
6.2.1 CONVEYOR ...................................................................................................................................... 14
6.2.2 DECAPPER....................................................................................................................................... 14
Function in factory ............................................................................................................................. 14
Spare Parts and their availability in Tech. store .................................................................... 14
6.2.3 FILLER .............................................................................................................................................. 15
6.2.4 RINSER ............................................................................................................................................. 15
Spare parts and their Availability in Technical Store ........................................................... 16
6.2.5 EXTERNAL WASHER ................................................................................................................... 16

6.3 BONFIGLIOLI ENGINEERING LEAK DETECTOR ....................................................................... 17
6.4 DOMINO CODING MACHINE............................................................................................................. 17
Model ....................................................................................................................................................... 17
6.5 ALTIVAR 28 INVERTER ...................................................................................................................... 17
6.6 ATLAS CAPCO AIR COMPRESSOR .................................................................................................. 18
Model ....................................................................................................................................................... 18
Spare part and their Availability in Technical store ............................................................. 18
6.7 INDUSTRIAL FRIGO CHILLER .......................................................................................................... 18
Model ....................................................................................................................................................... 18
6.8 ALFA LAVAL HEAT EXCHANGER.................................................................................................... 19
Model ....................................................................................................................................................... 19
6.9 DULCODES Z UV SYSTEM .................................................................................................................. 19
Model ....................................................................................................................................................... 19
6.10 PROMINENT OZONE GENERATOR & ACCESSORIES............................................................ 20
Models ..................................................................................................................................................... 20
6.11 PARTICLE FILTERS ........................................................................................................................... 21
Models ..................................................................................................................................................... 21
6.12 DOSING PUMPS ................................................................................................................................... 22
6.12.1 BRAN+LEUBBE METERING PUMP ...................................................................................... 22
Model ....................................................................................................................................................... 22
6.12.2 GRUNDFOS ALLDOS DOSING PUMP ................................................................................... 22
Model ....................................................................................................................................................... 22
6.13 REVERSE OSMOSIS TUBES ............................................................................................................. 22
Function ................................................................................................................................................. 22
6.14 ENDRESS + HAUSER MEASURING DEVICES ........................................................................... 23
6.14.1 PROMAG 50 .................................................................................................................................. 23
Model ....................................................................................................................................................... 23
6.14.2 LIQUIPHANT T ............................................................................................................................ 23
Model ....................................................................................................................................................... 23
6.14.3 CONDUMAX H CLS16................................................................................................................ 24
Model ....................................................................................................................................................... 24
6.14.4 SMARTEC S CLD134 ................................................................................................................. 24
Model ....................................................................................................................................................... 24
6.14.5 CEREBAR M PMP46 .................................................................................................................. 24
Model ....................................................................................................................................................... 24
6.15 ALLEN BRADLEY ELECTRONICS ................................................................................................. 25
6.16 INTERAPP PNEUMATIC ACTUATORS & ACCESSORIES ...................................................... 26
Models ..................................................................................................................................................... 26
6.17 JUNGHEINRICH FORKLIFT TRUCK ............................................................................................. 26
Model ....................................................................................................................................................... 26
7. SUGGESTED IMPROVEMENTS ........................................................................................................... 28
1. ABSTRACT
This is a report about the technical store of the Islamabad factory of Nestl Pakistan Ltd.
It discusses the classification of items, inventory levels, spare parts availability, under &
over stocked items as well as going over the list of critical spare parts machine-bymachine.
This report can be further used by the technical store manager to help maintain and
improve the store inventory and stock critical items to avoid production losses. It can
also be used to manage the current stock as it can help highlight several aspects,
including availability, non-moving items, ND items and criticality of items.
Page | 1
2. TECHNICAL STORE OVERVIEW

The technical store of the factory is responsible for keeping spare parts and other
general items in stock. The store manager is responsible for maintaining detailed
records of materials, their availability, their locations, issuance of materials and
remaining stock levels.
The technical store items can be divided into two categories:
1. ERSA
2. UNBW
ERSA items are spare parts and accessories of the machines. They are highly essential as
they are required when a machine breaks down. If ERSA is not maintained properly, it
could lead to line stoppage, delays and production & productivity losses.
UNBW items are general everyday items. They are not as essential as they do not affect
the productivity in the long run. All UNBW items can be restocked easily, cheaply and
locally so it does not lead to any major losses.
Page | 2
3. ERSA ITEMS
ERSA are important machine spare parts and accessories.
Currently, the technical store has 202 ERSA items. Out of these, only 127 are available
while 75 are unavailable.
Availability
37%
63%
Available
Unavailable
ERSA can be classified into two MRP Types: ND and VB. ND refer to No-Demand items
while VB items are still in demand. If any VB item reaches the Reorder Point, it is
automatically ordered while ND items need to be ordered manually, based on their
demands.
Based on criticality, ERSA can also be divided into A, B and C categories. A category
items are highly critical parts without which the whole production line can stop. C
category has low criticality items and production is not suffered if they are out of stock.
The MRP type and criticality classification of ERSA is given below:
MRP Type
Total Stock
C
8%
C
B
1%
A 9%
3% 13%
A
21%
MRP Type
Available Stock Only
B C
A 8% 1%
3% 12%
C
10%
88%
87%
B
58%
ND
VB
A
24%
B
54%
ND
VB
Page | 3
Total
A
B
C
ND
Total Available
179
112
44
31
118
69
17
12
Total
A
B
C
VB
Total Available
23
15
5
4
17
10
1
1
Based on current stock levels, ERSA can be classified into four categories:
1.
2.
3.
4.
Over Stocked
Under Stocked
Items that have reached Reorder Point
Rest
Stock Inventory
20 Items
16%
Overstocked
74 Items
58%
17 Items
13%
Understocked
Reorder Point
16 Items
13%
Rest
Page | 4
3.1 OVER STOCKED ITEMS

Currently, ERSA has 20 Over Stocked Items, with a combined worth of between 316,023
to 370,193.
Materials
146267693
146267817
146267818
146267748
146267815
146267821
146267822
146267824
146267825
146267837
146267827
146267784
146267692
146267700
146267711
146267717
146267820
146267832
146267851
146267846
Over
Stock
B
1
B
2
B
2
B
15
B
11
B
11
B
21
B
9
B
3
B
3
B
12
A
1
B
3
B
1
B
1
B
1
B
10
B
4
B
1
C
3
Grand Total
ABC
Price /
Unit
2,047
647
647
1,026
1,523
1,333
960
332
384
16,888
471
23,008
12,833
9,800
6,600
6,450
857
5,095
45,570
8,361
Min Money
Wasted
2,047
1,295
1,295
15,391
16,757
14,662
20,160
2,985
1,152
50,664
5,655
23,008
38,498
9,800
6,600
6,450
8,569
20,382
45,570
25,084
316,023
Max Money
Wasted
6,141
5,179
5,179
17,444
25,897
22,660
25,920
4,975
3,456
50,664
8,482
23,008
38,498
9,800
6,600
6,450
13,711
25,477
45,570
25,084
370,193
Unmoved For
(Days)
34
34
34
64
64
64
64
64
64
64
400
527
527
527
527
527
527
527
527
527
316,023
370,193
Money Wasted on Overstocked Items

400,000
183,960
194,197
350,000
121,771
151,015
250,000
200,000
150,000
50,000
Maximum Stock Condition

Minimum Stock Condition
5,655
8,482
100,000
4,636
16,499
Money
300,000
0
34
64
400
527
Total
Days since Unmoved
Page | 5
3.2 UNDER STOCKED ITEMS

Currently, ERSA has 17 Under Stocked Items, which would require 329,691 to 829,522
to restock.
Materials
ABC
146267746
146267749
146267750
146267751
146267753
146267683
146267684
146267723
146267721
146267729
146267782
146267783
146267791
146267792
146267708
146267752
146267850
Under
Stock
B
B
B
B
B
B
B
B
B
A
A
A
A
A
B
B
B
3
3
4
1
4
3
2
1
1
3
1
1
1
1
3
3
1
Cost/Unit
7,398
1,514
1,802
2,885
6,619
1,604
2,084
4,720
4,728
10,867
29,746
47,507
63,963
31,298
11,000
1,782
4,500
Grand Total
Min
Extra
Value
22,193
4,541
7,206
2,885
26,474
4,813
4,169
4,720
4,728
32,601
29,746
47,507
63,963
31,298
33,000
5,346
4,500
329,691
Max
Extra
Value
51,783
10,597
14,412
14,426
52,948
14,440
16,676
4,720
4,728
119,537
89,238
142,520
127,926
62,597
77,000
12,474
13,500
829,522
Unmoved For
(Days)
34
64
64
64
64
307
307
307
490
527
527
527
527
527
527
527
527
800,000
700,000
247,961
500,000
400,000
4,728
4,728
100,000
13,702
35,836
200,000
41,107
92,383
300,000
22,193
51,783
Money
600,000
34
64
307
490
329,691
644,791
900,000
829,522
Money Needed For Understocked Items
Minimum Stock Condition

Maximum Stock Condition
0
527
Total
Days Since Unmoved
Page | 6
3.3 ITEMS THAT HAVE REACHED REORDER POINT

Currently, ERSA has 16 items that have reached the Reorder Point. Out of these, 3 are
VB while 13 are ND. VB items would require 43,376, ND items would require 867,765
and collectively they would require 907,141 to restock.
ABC
B
B
B
B
B
A
B
B
B
B
B
B
B
C
C
C
MRP
Materials
Type
146267695 ND
146267849 ND
146267755 VB
103025882 VB
146267736 VB
146267839 ND
146267698 ND
146267757 ND
146267771 ND
146267772 ND
146267773 ND
146267798 ND
146267806 ND
146268109 ND
146268110 ND
146268111 ND
Grand Total
Cost/Unit
2400
4519
35000
4932.66
3443.5
13200
2600
2500
100537
75401
64632
1885
109010
5250
7700
350000
Unmoved
Extra
For
Value
(Days)
2400
64
4519
64
140000
64
9865.32
156
6887
521
13200
527
5200
527
5000
527
100537
527
75401
527
64632
527
7540
527
109010
527
5250
527
7700
527
350000
527
907141.3
Money Needed to Restock Items

885,786
900,000
722,115
800,000
Money
700,000
600,000
500,000
400,000
300,000
200,000
146,919
100,000
9,865
6,887
156
521
64
527
Total
Days since Unmoved
Page | 7
3.4 NON-MOVING ITEMS

ERSA items can also be classified as Non-Moving based on the time they have spent in the technical store without being used. Currently,
over 69.40 % of ERSA stock has been non-moving for the past 400 days while 61.25% has been non-moving for the past 527 days (17
months).
Non-Moving Stock
100%
90%
80%
Percentage of Stock
70%
60%
Total
50%
A
B
40%
C
30%
20%
10%
0%
34
64
125
156
215
307
337
400
429
446
490
521
524
527
Days since Unmoved
Page | 8
3.5 ERSA DUPLICATES

There were several duplicate entries in ERSA. These should be combined to ensure
better management.
S. No.
Material
1 146267780
146267707
2 146267743
146267749
3 146267755
146267756
146267769
4
146267775
5 146267808
146267807
6 146267728
146267771
Material Description (EN)

Contactor Magnetic (ABB France )
Contactor Magnetic ABB
Gasket Butterfly Valve DN 40mm EPDM
Gaskit Batterfly Valve DN 40 EPDM
Gauge Pressure WIKA Type M93X.3A
Gauge Pressure WIKA Type M93X.3A
Kit Unloading Atlas Capco 2901-1101-00
KitUnloadingValve AtlasCapco2901-110100
Sensor Proximity 24 VDC P+F 85971
Sensor Proximity Sick 24 VDC
Dozing Pump BRAN+LUEBBE-P33
Kit Dozing Pump BRAN+LUEBBE
MRP
Type
ND
ND
ND
ND
VB
VB
VB
Store
Inventory
0
0
0
5
4
7
0
ND
VB
ND
ND
ND
0
0
0
1
Page | 9
4. UNBW ITEMS
UNBW are everyday general purpose items.
UNBW classification is given below:
ND
PD
Sum
Total
Available
A
B
6
84
17
13
23
97
158
Unavailable
A
B
8
34
7
3
15
37
100
C
24
14
38
C
44
4
48
258
UNBW Classification
100%
PD 1.6%
C
18.6%
90%
Unavailable
38.8%
80%
70%
A 5.8%
60%
50%
B
14.3%
C
14.7%
100.0%
ND
17.1%
PD 1.2%
ND
13.2%
PD 2.7%
ND 3.1%
PD 5.4%
ND 9.3%
PD 5.0%
40%
Available
61.2%
30%
B
37.6%
20%
10%
0%
Total
Availability
ND
32.6%
A
8.9%
PD 6.6%
ND 2.3%
ABC
ND/PD
Page | 10
5. SPARE PARTS
Spare Parts are an essential part of any factory. They ensure that production does not
stop or slows down in case of any technical problems with the machines or equipments.
The spare parts classification of Islamabad factory is given below, with detailed
discussion about each machine later on in the report.
A
B
C
Sum
Total
Available Unavailable
40
14
53
40
14
30
107
84
191
Spare Parts Classification

C
16%
A
21%
44%
B
21%
56%
A
7%
B
28%
C
7%
Available
Unavailable
Page | 11
6. DETAILED LIST OF SPARE PARTS

ACCORDING TO MACHINES
Page | 12
6.1 GENERATORS
6.1.1 CATERPILLAR 365KVA GENERATOR
Function in Factory
Caterpillar 365KVA generator is used as a substitute when electrical power from
WAPDA is unavailable. It has the capacity to handle the entire load of the factory.
Spare Parts and their Availability in Technical Store

Lubricants that are recommended by caterpillar follow CAT ECF standards. Caterpillar
recommends the use of either of following lubricants produced by Caterpillar for
maintaining the efficiency of the engine as well as to prevent wear:
1. Cat DEO (10W-30)
2. Cat DEO (15W-40)
3. Cat DEO-ULS (15W-40)
Spare parts that must be present for proper maintenance are as under:
Spare Part
B
B
B
B
B
Availability in
Technical Store
Unavailable
Available
Unavailable
Unavailable
Unavailable
Available
ABC
1.
2.
3.
4.
5.
Air Cleaner
Engine Oil
Fuel Filter
Fuel Water Separator
Lubricants/Engine Crank Case
Fluid
6. Oil Filter
Material Number Assigned

by Technical Store
146267730
103239916
146267733
146267743
146267736
6.1.2 CUMMINS 50KVA GENERATOR

Model
C55D5
Function in Factory
This generator is automatic. Thus, it maintains a continuous power supply, even when
the WAPDA goes off, ensuring that the production does not stop even for a second. Its
main function is to ensure that the Well doesnt stop as restarting it takes some time.

Spare Part
ABC
1. Air cleaner
2. Fuel Filter
3. Oil Filter
B
B
B
Availability in
Technical Store
Available
Unavailable
Unavailable
Material Number Assigned by

Technical Store
103025882
103025928
103025920
Page | 13
6.2 TECHLONG SYSTEMS

6.2.1 CONVEYOR
Function in Factory
Conveyor system carries the bottle through each and every step in the factory
production floor.

Spare Part
B
B
Availability in
Technical
Store
Available
Available
146267678
146267686
Available
146267714
B
B
B
B
Available
Available
Unavailable
Unavailable
Available
146267834
C
C
C
C
C
Available
Available
Available
Available
Available
2619, 2620 (Zero Value)

2619, 2620 (Zero Value)
2604, 2606 (Zero Value)
2605 (Zero Value)
15821
ABC
1. Bearing 51203
2. Bearing UCF205
3. Belt Conveyor Rubber
400x6500
4. Conveyor Chain Plastic
5. Conveyor Chain SS
6. Driven Wheel, Linear Conveyor
7. Driving Wheel, Linear
Conveyor
8. Switch Photo Electric Banner
QS18EN6LP
9. Driven Shaft
10. Driving Shaft (NMRV063)
11. Flat Strip, 35x6 (WxB)
12. Flat Strip, 70x5 (WxB)
13. Motor Reducer

by Technical Store
2616 (Zero Value)

2615 (Zero Value)
6.2.2 DECAPPER
Function in factory
It is used to remove the caps from empty 5 gallon bottles.
Spare Parts and their availability in Tech. store

Spare Part
1.
2.
3.
4.
Cylinder 32x150
Cylinder 32x35
Reflector Sensor
Jaws
ABC
B
B
B
C
Availability in
Technical Store
Available
Available
Unavailable
Unavailable

Technical Store
146267718
146267721
Page | 14
6.2.3 FILLER
Function in Factory
Filler fills the bottles with 5 gallon water. There are 6 nozzles for filling 6 bottles
simultaneously. A sensor counts the bottles and when the count reaches 6, the filling
begins. It can also fill 5 bottles.

ABC
Availability in
Technical Store
Electromagnetic Flow Meter DN40

Gear Box Conveyor MOTOVARIO I:20
Bearing 6206-2RZ
Bearing Holder(UCF 205)
Bevel Gears
Driven Wheel, Linear Conveyor
Driving Wheel, Linear Conveyor
Filling Valve
A
A
B
B
B
B
B
B
Available
Unavailable
Available
Available
Available
Unavailable
Unavailable
Unavailable
9. Gasket Manual Butterfly Valve DN38
10.
11.
12.
13.
14.
15.
16.
B
B
B
B
C
C
C
Spare Part
1.
2.
3.
4.
5.
6.
7.
8.
Gasket Pneumatic Butterfly Valve DN25.4

Gasket Pneumatic Butterfly Valve DN63.5
Motor i=1:30
Sampling Valve DN15
(Cap Stop) Tension Spring
Compressed Spring DG06F.03-10-070752
Driven Shaft
17. Driving Shaft

18. Guide Steel Wire
19. Spring DG06F.03.06-10-070752
C
C
C
Material Number
Assigned by
Technical Store
146267741
146267758
146267680
146267686
146267692
146267670
146267743,
Available(DN40)
146267749
Available(DN25) 146267748
Available(DN65) 146267751
Available
146267759
Available
146267846
Unavailable
Unavailable
Available
2619, 2620 (Zero
Value)
Unavailable
Unavailable
Unavailable
6.2.4 RINSER
Function in Factory
Rinser has four stages:
1. Internal Rinsing with Water
2. Internal Rinsing with Alkaline Solution
3. Internal Rinsing with Hydrogen Peroxide (H2O2)
4. Internal Rinsing with Ozonated Water
After internal rinsing, the bottles move on towards the filling section where they are
filled and capped.
Page | 15
Spare parts and their Availability in Technical Store

1. Bottle Clamp Cup
Availability in
Technical Store
Available
2. U Heating Pipe
Available
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
B
B
B
B
B
B
B
B
B
B
C
C
C
C
Available
Unavailable
Unavailable
Unavailable
Unavailable
Available
Available
Unavailable
Unavailable
Unavailable
Unavailable
Unavailable
Unavailable
Unavailable
Spare Part
ABC
Cylinder 32x100
Cylinder 40x200
Cylinder 40x250
Heater 32kW
Level Probe
Lower Spray Nozzle
Motor Reducer i=60
Pneumatic Butterfly Valve
Pressure Manometer
Water Pump
Bottle Supporting Plate
Screw Assembly
Shaft Holder
Sprocket

Technical Store
146267885
146267841,146267842, 2608
(Zero Value)
146267717
146267722
146267724
2617 (Zero Value)
15826
6.2.5 EXTERNAL WASHER

Function in Factory
External washer washes the bottles externally with the help of brushes.

B
B
B
B
B
B
B
Availability in
Technical Store
Available
Available
Unavailable
Unavailable
Available
Available
Unavailable
B
B
B
B
B
B
Available
Available
Unavailable
Available
Unavailable
Unavailable
14. Reducer
Available
15. Small Sprocket

16. Wear Strip 35x6
C
C
Available
Available
Spare Part
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Base Brush
Bearing 61902RZ
Bearing 7005AC
Bearing 7005C
Bearing 7006C
Bearing 7210AC
Bearing
GTM2644
Bearing UCF205
External Brush
Heater 18kW
Motor 0.37kW
Vertical Brush
Water Pump
ABC

Technical Store
146267698
146267679
146267681
146267682
146267683
146267684
146267686
2621 (Zero Value)
15825
146267699
146268102 (Unavailable),
146268103, 146268104
146268101
2604, 2606 (Zero Value)
Page | 16
6.3 BONFIGLIOLI ENGINEERING LEAK DETECTOR

Function in Factory
It is used for the detection of bottles that have a leak.

Spare Part
1.
2.
3.
4.
5.
6.
ABC
Availability in
Technical Store
B
B
B
B
B
B
Unavailable
Unavailable
Available
Available
Available
Available
Photoelectric Sensor
Pneumatic Cylinder 32
Pneumatic Cylinder 32x100
Pneumatic Cylinder 32x150
Solenoid Valve 2/2
Solenoid Valve 5/2
Material Number
Assigned by Technical
Store
146267719
146267717
146267718
146267849
146267850
6.4 DOMINO CODING MACHINE

Model
A200 GP
Function in Factory
It is used to print the Best Before dates on the bottles.

Spare part
1.
2.
3.
4.
ABC
Ink Reservoir IR 272 BK

Ink Reservoir IR 295 BK
Make up MC 272 BK
Make up MC 299 BK
A
A
A
A
Availability in
Technical Store
Unavailable
Available
Unavailable
Available
Material number assigned

by Technical store
146268032
146268033
146268034
146268035
6.5 ALTIVAR 28 INVERTER

Function in Factory
It is connected to the submersible pump deep water well, controlling the pumps speed.

Spare Part
1. Complete Unit (Altivar 312)
ABC
B
Availability in
Technical Store
Available

Technical Store
2614 (Zero Value)
Page | 17
6.6 ATLAS CAPCO AIR COMPRESSOR

Model
ZT30
Function in Factory
It provides compressed air around the factory wherever it is required, for example, in
Air Handling Unit (AHU) and Ozone Generators.
Spare part and their Availability in Technical store

Spare Part
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
ABC
Air Filter
Breather Kit
Coupling Rubber 1622-1136-02
Filter Element PD 120
Filter of Gear Casing Breather
Kit Service Oil Pump
Kit Unloading Valve
LED/Display
Muffler
Oil Filter
Roto-Z Oil
Safety Valves
Fuse 33A
Fuse 3x80 gL/gG
B
B
B
B
B
B
B
B
B
B
B
B
C
C
Availability in
Technical Store
Unavailable
Available
Unavailable
Available
Available
Available
Unavailable
Unavailable
Available
Unavailable
Available
Unavailable
Available
Available

by Technical Store
146267731
146267774
146267716
146267732
146267768
146268100
146267769, 146267775
146267796
146267737
146267937
2583 (Zero Value)
2581 (Zero Value)
6.7 INDUSTRIAL FRIGO CHILLER

Model
GRW 13/X
Function in Factory
It is used to provide cold water to ozone generators.

Spare Part
1. Controller
(Temperature)
2. Pressure Sensor
3. Temperature Sensor
4. Thermostatic Valve
ABC
Availability in
Technical Store

by Technical Store
Available
146267713
B
C
C
Unavailable
Available
Unavailable
146267830
Page | 18
6.8 ALFA LAVAL HEAT EXCHANGER

Model
M10-MBASE
Function in Factory
Heat Exchanger is used to keep a constant temperature of CIP water to ensure the pipes
do not crack. It is installed in the Water Treatment Area in Islamabad factory

Spare Part
1. Gaskets
2. Kit Service SolidC-1
9611922454
9611922471
9611922487
5. Seal Kit Pump
9611129601
6. Seal Kit Pump C1 EPDM
Availability in
Technical Store
Available
Available
Available
Available
Available
146267809
Available
146267813
ABC

by Technical Store
146267832
146267810, 2622 (Zero
Value)
146267811, 2623 (Zero
Value)
146267812, 2624 (Zero
Value)
6.9 DULCODES Z UV SYSTEM

Model
3x300Z Dulcodes Z UV System
Function in Factory
UV System is used to disinfect the water by killing the bacteria. It is installed in the
Water Treatment Area in Islamabad Factory.

Spare Part
1.
2.
3.
4.
5.
Electronic Card
Lamp Protective Tube 300 Z
UV Lamp 300 W Opti Flux
UVC Sensor Z
3x300 Z: Sensor Window: G1x30
ABC
A
A
A
A
B
Availability in
Technical Store
Available
Unavailable
Available
Unavailable
Available

by Technical Store
146267703
146267843
146267844
146267831
146267851
Page | 19
6.10 PROMINENT OZONE GENERATOR &

ACCESSORIES
Models
OZONFILT OZVa 1
OZONFILT OZVa 2
DGMa
Dulcotest OZE 3-mA-2 ppm
Dulcometer D1C
OZVa 1 and 2 are distinguished on the bases of their ozone generated per hour. OZVa 1
has an ozone generation rate of 5 g/hr where as OZVa 2 is a bigger unit, which
generates ozone at the rate of 15 g/hr.
Function in Factory
Ozone generator is used for water treatment. It treats water with ozone gas for
disinfecting water. Ozone generators generate ozone through electrical discharge and
mix the ozone gas with water. There are three ozone generators (2xOZVa1, 1xOZVa2) in
Islamabad factory.
DGMa and Dulcotest are used to check the levels of Ozone being produced.
Dulcometer is a device designed for measuring, displaying and controlling measures
variables. The measured variables to be processed are:
pH, ORP
Standard Signal, Temperature
Dissolved Oxygen
Chlorine, CLO2, Br, O3
Conductivity
H2O2, Per acetic Acid

Each spare part must be present for both OZVa 1 and OZVa 2.
1. Dulcometer Key Pad

2. Dulcotest Compete Unit
A
A
Availability in
Technical Store
Available
Available
3. Electronic Controller
Available(OZVa1,2)
4.
5.
6.
7.
A
A
A
Available
Unavailable
Available
Available
A
A
Available(OZVa1,2)
Available
Spare Part
Gas Flow Meter OZVa 1

Gas Flow Meter OZVa 2
HV Transformer OZVa1
Key Programming
100067/1174
8. Power Unit
9. Thermister 55C 2455R
ABC

by Technical Store
146267767
146267829
146267676, 146267701,
146267702 (Unavailable)
146267672
146267673
146267763
102958856
146267675,146267674
146267839
Page | 20
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Tube Ozone Generator

Door Trip Switch
Dulcometer Display Panel
Valve Flow Control O3 Sensor
1000CBABABAA
Absorber Drier
Air Cleaning Unit Filter
HV Transformer OZVa2
HV Transformer Power Supply
Membrane Cap O3 Sensor
790488
No-Return Valve, Ozone Inlet
Process Air Regulating Valve
Regenerating Air Regulating
Valve
Solenoid Valve, Compressor
A
B
B
Unavailable
Available(OZVa1,2)
Unavailable
146267799
146267851
146267726
Available
146267845
C
C
C
C
Unavailable
Unavailable
Unavailable
Unavailable
Available
C
C
C
Unavailable
Unavailable
Unavailable
Unavailable
146268099
146267840
6.11 PARTICLE FILTERS

Models
10
5
1
0.6
Function in Factory
Filters are used in the water treatment area to separate the solid particles from the
water. Filters of various resolutions are installed in the Water Treatment Area in
Islamabad factory.

Spare Part
1.
2.
3.
4.
Filter 0.6
Filter 1
Filter 5
Filter10
ABC
A
A
A
A
Availability in
Technical Store
Available
Available
Available
Available

Technical Store
146268016, 146268018
103028187, 146267739 (Unavailable)
146268010, 146268011
146268009, 146268017
Page | 21
6.12 DOSING PUMPS

6.12.1 BRAN+LEUBBE METERING PUMP
Model
Novados H1-EP33
Function in Factory
Novados Dosing Pump is used to introduce controlled quantities of chemicals (CaCl2,
MgSO4, NaHCO3) to water to re-mineralize it.

Spare Part
1. Complete Pump
Availability in
Technical Store
Available
ABC
A

Technical Store
146267728, 146267771
6.12.2 GRUNDFOS ALLDOS DOSING PUMP

Model
DMX 380-3
Function in Factory
It is used to control the volume flow of CIP (Cleaning-in-Process) lines. It is installed in
the Water Treatment Area in Islamabad factory.

Spare Part
Availability in
Technical Store
Available
Unavailable
ABC
1. Kit Process Pump

2. Dosing Diaphragm
B
C

Technical Store
146267772
6.13 REVERSE OSMOSIS TUBES

Function
Function of these tubes is to carry out the process of reverse osmosis.

Spare Part
1. Reverse Osmosis Filter
Membranes
ABC
Availability in
Technical Store
Available

by Technical Store
146268008
Page | 22
6.14 ENDRESS + HAUSER MEASURING DEVICES

6.14.1 PROMAG 50
Model
Promag 50H80
Function in Factory
Promag 50 is an electromagnetic flow measuring device for de-mineralized water in
closed pipes. There are several installed in the Water Treatment Area in Islamabad
factory.

Spare Part
1. Complete Unit
2. Power Supply Board
ABC
C
C
Availability in
Technical Store
Available
Unavailable

Technical Store
146268111
146268112
6.14.2 LIQUIPHANT T
Model
Liquiphant T FTL20H
Function in Factory
It is a level limit switch used for level limit detection in liquids.

Spare Part
1. FPM O-Ring for Weld-in Socket
1
2. Socket Spanner 32AF for
Process Connection 52010156
3. Weld-in Adapter 52001047
4. Weld-in Socket G1 52001051
5. Weld-in Socket G3/4 52018765
ABC
Availability in
Technical
Store
Unavailable
Unavailable
C
C
C
Unavailable
Unavailable
Unavailable
Material Number
Assigned by Technical
Store
Page | 23
6.14.3 CONDUMAX H CLS16

Model
Condumax H CLS16
Function in Factory
CLS16 is a conductivity sensor. It is a fixed cable or connector version with integrated
temperature sensor, with cell constant k = 0.1 cm-1.

Spare Part
1. Complete Unit
ABC
A
Availability in
Technical Store
Available

Technical Store
146267706
6.14.4 SMARTEC S CLD134

Model
CLD134
Function in Factory
CLD134 is a conductivity measuring device.

Spare Part
1. Complete Unit
ABC
B
Availability in
Technical Store
Unavailable

Technical Store
6.14.5 CEREBAR M PMP46

Model
Cerebar M PMP46
Function in Factory
Cerebar M PMP46 is a pressure transmitter for measuring pressure level. There are
several installed in the Water Treatment Area in Islamabad factory.

Spare Part
1. Complete Unit
ABC
B
Availability in
Technical Store
Available

Technical Store
146267806
Page | 24
6.15 ALLEN BRADLEY ELECTRONICS

Function in Factory
Allen Bradley electronics are installed at various locations in the factory, including
Frequency Inverters, Display Panels, I/O Modules etc.

Spare Part
1.
2.
3.
4.
5.
6 Channel Input Module 17691R6

Analog Module 4 Chanel 17691FB
Analog Module 8 Chanel 17691F4
Counter Module 24VDC 1769SDNB
Device Net Counter Module 1738
VSHC24
6. Device Net Module 1606 * LDNET8
7. Device Net Module 17388 EP
8. Device Net Module 17691Q32
9. Device Net Power Supply
1606L960E-3
10. Display Panel ViewPlus10 2711PT10C4D8
11. Ether Net Module 1734EP24DC
12. Expansion Point I/O 1734-TOP
13. Frequency Inverter Power flex 400
14. Input Module 1769-IQ32
15. Output 32 PT Module
1769SDNBA01
16. Power Supply 1738 ADN12
17. Power Supply 1769-PA4
18. Power Supply PLC 1769L35E
19. Power Supply PLC L43 1768PB3
20. Power Tap DeviceNet 1788EN2DN
21. Terminal Ether Net to Device Net
1485T-TP2T5-5
22. Frequency Inverter 1.75 kW
23. Frequency Inverter 3 kW
A
A
A
A
Availability in
Technical Store
Available
Available
Available
Available
Available
146267788
A
A
A
Unavailable
Available
Available
146267785
146267786
146267787
Available
146267802
Unavailable
146267727
A
A
A
A
Available
Available
Available
Unavailable
146267789
146267729
103024697
146267790
Available
146267792
A
A
A
A
A
Available
Available
Unavailable
Unavailable
Unavailable
146267800
146267801
146267803
146267804
146267805
Unavailable
146267838
B
B
Unavailable
Unavailable
146267764
146267765
ABC

by Technical Store
146267791
146267782
146267783
146267784
Page | 25
6.16 INTERAPP PNEUMATIC ACTUATORS &

ACCESSORIES
Models
InterApp IA100D Pneumatic Actuator

InterApp IA100D+Hub Pneumatic Actuator
InterApp IA200D Pneumatic Actuator
InterApp IA200D+Hub Pneumatic Actuator
InterApp ES2.P01HIP65 Limit Switch Box
Function in Factory
IA 100D, 200D are pneumatic actuators, which convert energy (typically in the form of
compressed air) into mechanical motion.
ES2 Limit Switch Box is an SPDT (Single Pulse Double Throw) switch, directly mounted
on pneumatic actuator. It provides a visual and remote electrical indication of quarter
turn actuator position.
Several Actuators and Limit Switch Boxes are installed in the Water Treatment Area in
the Islamabad factory.

Spare Part
1.
2.
3.
4.
5.
InterApp IA100D.F05-F0711
InterApp IA100D.F05-F0711+Hub
InterApp IA200D.F05-F0711
InterApp IA200D.F05-F0711+Hub
InterApp Limit Switch ES2.P01H
ABC
A
A
A
A
B
Availability in
Technical Store
Available
Available
Available
Available
Available

by Technical Store
2610 (Zero Value)
2611 (Zero Value)
2612 (Zero Value)
2613 (Zero Value)
2609 (Zero Value)
6.17 JUNGHEINRICH FORKLIFT TRUCK

Model
EJD 220
Function in Factory
This forklift truck has the capacity to lift loads of up to 2000kg and is used for moving
bottles placed in pallets from the production line to the outside of factory from where
they are loaded in vehicles for distribution.
In Islamabad factory, a pallet contains 32 bottles which collectively weigh over 600kg.

Electrical fuses are the most critical components for this forklift truck as it would stop
functioning if even one of the fuses blow.
Page | 26
Spare Part
1. Hour Meter
2. Specified Lubricants for Hydraulic
System, Transmission and Chains
etc.
3. Drive Motor Fuse (150A)
4. Drive Motor Fuse (40A)
5. Overall Control Fuse (10A)
6. Pump Motor Fuse (150A)
Availability in
Technical Store
Available
Unavailable
C
C
C
C
Unavailable
Unavailable
Unavailable
Unavailable
ABC

by Technical Store
2539 (Zero Value)
Page | 27
7. SUGGESTED IMPROVEMENTS
Zero Value Items should be entered into ERSA or UNBW as soon as possible.
Technical Store should have its own computer with network access for easy
access to SAP.
Technical store manager should have rights to add data to SAP for easy record
keeping.
Technical Store should be fully air-conditioned as some equipment (bearings

etc.) need to be kept at a low temperature.
Page | 28

Nestle Water, Pakistan

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Nestle Water, Pakistan

Uploaded by

Copyright:

Available Formats

TECHNICAL STORE AND

SPARE PARTS ANALYSIS

GHULAM ISHAQ KHAN INSTITUTE OF ENGINEERING SCIENCES

TECHNICAL STORE OVERVIEW...................................................................................................... 2

ERSA ITEMS ............................................................................................................................................ 3

UNBW ITEMS ......................................................................................................................................... 9

SPARE PARTS ....................................................................................................................................... 11

DETAILED LIST OF SPARE PARTS ACCORDING TO MACHINES ...................................... 12

6.1 GENERATORS ......................................................................................................................................... 13

Function in Factory ............................................................................................................................ 16

2. TECHNICAL STORE OVERVIEW

3.1 OVER STOCKED ITEMS

Money Wasted on Overstocked Items

Maximum Stock Condition

Days since Unmoved

3.2 UNDER STOCKED ITEMS

Money Needed For Understocked Items

Minimum Stock Condition

Days Since Unmoved

3.3 ITEMS THAT HAVE REACHED REORDER POINT

Money Needed to Restock Items

Days since Unmoved

3.4 NON-MOVING ITEMS

Days since Unmoved

3.5 ERSA DUPLICATES

Material Description (EN)

Spare Parts Classification

6. DETAILED LIST OF SPARE PARTS

Spare Parts and their Availability in Technical Store

Material Number Assigned

6.1.2 CUMMINS 50KVA GENERATOR

Spare Parts and their Availability in Technical Store

Material Number Assigned by

6.2 TECHLONG SYSTEMS

Spare Parts and their Availability in Technical Store

2619, 2620 (Zero Value)

Material Number Assigned

2616 (Zero Value)

Spare Parts and their availability in Tech. store

Material Number Assigned by

Spare Parts and their Availability in Technical Store

Electromagnetic Flow Meter DN40

9. Gasket Manual Butterfly Valve DN38

Gasket Pneumatic Butterfly Valve DN25.4

17. Driving Shaft

Spare parts and their Availability in Technical Store

1. Bottle Clamp Cup

Material Number Assigned by

6.2.5 EXTERNAL WASHER

Spare Parts and their Availability in Technical Store

15. Small Sprocket

Material Number Assigned by

6.3 BONFIGLIOLI ENGINEERING LEAK DETECTOR

Spare Parts and their Availability in Technical Store

6.4 DOMINO CODING MACHINE

Spare Parts and their Availability in Technical Store

Ink Reservoir IR 272 BK

Material number assigned

6.5 ALTIVAR 28 INVERTER

Spare Parts and their Availability in Technical Store

Material Number Assigned by

6.6 ATLAS CAPCO AIR COMPRESSOR

Spare part and their Availability in Technical store

Material Number Assigned