A

REPORT ON
INDUSTRIAL VISIT AT PEPSICO
(GOA BOTTLING PLANT)

Submitted to: Submitted By:

Arun Singh Chauhan Jain Jitendra Deepak Kumar
H.O.D (C.S.) 07EMHCS017

Our Sincere Thanks to:

Tour Incharge: Mr. Prakash Baharani
Principal: Dr. A.K.Arora
MAHARISHI ARVIND INTERNATIONAL INSTITUTE
OF TECHNOLOGY, KOTA (RAJ.)
1
 Industry Visit to Pepsi Plant, kurti(GOA)

On January24, 2010, Maharishi Arvind International Institute Of technology 3 rd year students are
taken at PepsiCo plant in Kurti(GOA) to understand the work process & culture of an MNC.

The students were taken through the entire bottling process from the first stage of Perform
making to blowing of the bottle till the last stage viz. packaging & storage. It was a great
learning for the students to know that soft drink bottle or any SKU (stock keeping unit) goes
through 400 stages of tests, which makes every bottle or tetra pack unit a world class product.
The quality standards are stringent and the same are standardized across the world, without
exception.

Students could understand & are now able to relate all the concepts taught in the class e.g.
concept of work, differentiation between paid & unpaid work, assembly-line, alienation, de-
skilling, up-skilling, system of mass production & mass consumption, team working, total
quality management (TQM), Just in Time production system (JIT), flexible manufacturing
system (FMS), adaptable marketing system (AMS), etc.

The students learnt about:

 Hiring of Quality People: First, we were briefed about the updated profile of people
working in the organization categorized under various sub-heads as per there capabilities
and working strategies (specialization / Up-skilling). Alienation & De-skilling were on
the lower side.

2
 Modified Assembly Line: manufacturing process in which parts (interchangeable parts)
are added to a product in a sequential manner. It is used to create the finished product in a
faster manner than handicraft /manual type method. Mass production with the help of
assembly-line technique in the factory helped in meeting the demand for the product,
thus, creating goodwill in the market by the easier technique of assembly-line.

 Standardization of Process: These are across all the plants of PepsiCo system & norms
are adhered without exception. Being one of the most recognized brands all over the
world, standardization or the technicality and quality of the product was considered as
essential criteria while processing the product.

 Conveyor belt/ arrangement: configured and disposed to move cleaned bottles from
cleaning station to filling machine. A well developed process to reduce time and result in
a product which can be relied upon as it goes through a technical process hence,
reinforcing the standard and quality to be up to the mark.

 High Quality/ customized product despite stage production: The plant lines were running
at the speed of 400 BPM (Bottle per Minute) & every bottle so closely inspected by line
inspector, that it was amazing to know that every bottle produced is a world quality
bottle.

 Mechanization: The entire plant was so mechanized that there were very few people
manning the line / machines.

 Good house keeping: The entire plant was so well done up, that it shows that iconic
products got produced in an environment which is hygienic & process driven.

3
 Team Work: Team comprises of unskilled, semi-skilled & skilled workers /professionals.
It appears to the eye that ten people produce a billions beverage bottle in a year The
entire operators were an ideal example of team work by a set of people whose common
objectives was to produce a world class product. The worker distinction of unskilled,
semi-skilled and skilled workers did not interrupt in the chance of improving one's
knowledge as all the workers were able to see the procedures and gain knowledge in
order to improve their skills. A clear usage of the concept of white-collar and blue-collar
jobs is maintained.

Overall it was a great experience for young minds of MAIIT

4
 Student's Perspective about Industry Visit to PepsiCo
UBS Stage-1

24th
On January 2010, Sunday , The students of MAIIT(KOTA) 3rd year went for an industrial
trip to a private owned company of PepsiCo located in Kurti(GOA) in the Industrial village. The
industrial guide first showed the Blow Room where the raw material used for making the raw
materials is used to bring it to the original size used for filling. The raw material comes in small
tube like bottles which are really small in size and are heavy plastic. The plastic is then heated up
and melted , once melted it is allowed to condense and then its blown by the air pump to make
into the desired size of the bottle. Once these bottles are made they are sent to the cleansing room
, where the impurities inside the bottle are removed by air blown disinfectants . After this stage ,
they are sent to the filling section where the bottles are filled. The company manufactures Pepsi,
Nimbooz and Slice at this plant . Once the bottles are filled , the next phase is the sealing phase.
The bottles are filled with phenylalanine, which is carbonated gas used to make the drink fizzy
till it is open to drink. It’s the drink preservative. After that the bottles are sealed with air tight
plastic covers in the packaging system. The bottles are not yet labeled. The next step is the
heating room where the bottles are heated at a temperature of 80 Celsius in order to kill all the
existing bacteria over the bottles. Once the sealing is completed, to check the quality and have a
counter check, the bottles are sent through a belt to see whether the bottles are finally ready for
consumption. In order to maintain the quality, the bottles are screened via a passage in which it
passes through the x-ray plate wherein 2 people are asked to keep a check on whether the bottle
contains any impounded particles and hence, a defected product can be distinguished and re
utilized. It was an great example of Total Quality Management (TQM)/ Zero Error. A very
important feature for the workers that proper guidance related to the eye check within a regular
time period of work is also provided which shows that the product standardization as well as the
workers satisfaction and care is taken by the organization in order to maintain the workers level
of satisfaction. They are then thoroughly washed to remove all visible impurities. The most
important and difficult part of the manufacturing system is the light room , where normal 600mm
tube lights are used to see through the bottles by manual labor to see if any unwanted material is
present in the bottles or if the bottles are filled more or less than the required amount. The glass

5
bottles are 100% filled, whereas as the plastic bottles are 90 % filled. The loss bared by the
company subjects to 50% of the cost incurred at the time of production. The bottles are then sent
to the packaging section where the respective covers and labels of the bottles are sealed. The
company packs 96 bottles per box in a minute. Then later on the boxes are then safely sent to the
warehouses and then delivered to the markets as per the requirement of the consumers. Even the
distribution process is made sure to be under proper guidance in order to make the availability of
the product as per its requirement in the market without any criteria of shortage of the product.

Another important learned aspect is "When we sit in a class and learn all the acronyms of
environmental regulations, it's abstract". But when we went out and saw the plant, we actually
understood the real world." This gives us an insight about the environmental regulations
followed by the company such as waste reduction programmer which saves company’s lot of
money. Overall we could clearly understood the concepts of work, assembly line, alienation,
Zero error, flexible manufacturing system, adaptable marketing system, and above all we
realized that this entire work process & success is not possible without team work.

We would like to thank and Mr. Prakash Baharani for a successful Industrial visit which could
actually help us to apply our theoretical knowledge in practical and create a good understanding
of the concepts.

UBS Stage 1

PHOTOGRAPHS ATTACHED

6
CONVEYOR BELT

CONVEYOR BELT

7
 BLOWMOULDER

PARAMIX

PARAMIX
8
FILLER

9
10