1. Plants in Kay-Cee Distillery § Fermentation Plant § Distillation Plant § Bottling Plant

2. Problems Reported Full capacity of the line was not realized Breakage of bottles Existing Lack of good plant layout Inefficient machines utilization Breakage of bottles in the line

3. The line consists of the following Machines: Bottle washer Filling machine Sealing machine Inspection zone Labeling machine Packing conveyor

4. Breakage of Bottles `` and free falling on the conveyor In Filling machine - Due to improper height In sealing machine - Due to improper height In Labeling machine- Due to entry fault into screw conveyor

5. Solution for Bottle Washer Breakage Purchase of bottles from a vendor who supplies standard bottles of size and shape By placing a thin cushion lining at the bottle free fall position in the Bottle washer

6. Solution to breakage in Filling and Sealing machine By checking the height of the bottles entering the system Over sized bottles, sensed by an optical method, are ejected pneumatically from the conveyor

7. Solution to Breakage in Labeling machine Checking for continuous flow of bottles optically sensing the gap between bottles and stopping the flow into the labeling conveyor

8. Automatic Inspection Need Takes more time when done manually More errors due to fatigue of operator eye strain repeated or cyclic work Procedure using photo sensor to identify the defects eliminating the bad product by pneumatic ejector

9. Automatic Case Packing Machine Need for faster packing synchronization of the process Process Pneumatic grippers are used to pick up bottles casing jigs are used for placing the bottles in the carton

10. Re-layout Need The existing layout of the plant is inefficient It needs a lot of manual operation consumes more time looks awkward

11. Improvised LayoutLayout Taking the bottles to machines using a conveyor taking shortest rectilinear way to the machines joining all the machines in a continuous flow line

13. Bottle Washer Specification Bottle size/shapeflat Capacity100-120 BPM Overall Dimensionlength 14 feet width 6 feet height 7 feet Washing cycles3cycles raw water 3cycles soft water back