Khurda, Odisha

Classified - Internal use

Outline of Company

Global Vision & Mission

Achieve Safety Excellence through Behaviour Change

About Us
HCCB is organized into 7 operating Zones split by Geography

25 Bottling Units for manufacturing & Distribution in India.

Operation is divided in to 7 Zones.
Corporate Office Located in Gurgaon.
Total No of Employees 9247
Total Business operation in Revenue 8000 Cr

HCCBPL, Khurdha
Internal Use Only
Classified - Internal use

Factory Overview
Plot size

38 acres
6 Lines

Product Portfolio
RGB CSD (200 & 300 ml)

:- Fanta, Coke, ThumsUp, Sprite

RGB Maaza (200 & 250 ml)

: Maaza

PET CSD (600,1250,2000, 2250 ml)

: Kinley Soda, Thums Up, Sprite,Coke,Fanta

Retail Water (1000 ml)

: Kinley Water

Tetra Pak (200ml)

: Maaza

Plant Capacity

Abbreviation

RGB

: 600 BPM
: 600 BPM
: 140 BPM
: 75 BPM
: 600 BPM
: 400 PPM
: Retainable Glass Bottles

RGB CSD

RGB Maaza

Our Product Range

RGB CSD
RGB Maaza
PET CSD
Retail Water
PET CSD Krones
Tetra Pak

Tetra Pak

PET CSD
140
KINLEY
water
PET Krones
600 BPM

CSD : Carbonated Soft Drink

PET : Polyethylene Terephthalate

Plant History

68% Growth

Khurda Unit is a part of Combined East Zone

20

in HCCBPL.

Capital city of Odisha, an area of 38 acres.

Its Green filed Project started its Operation in the

year 1999

15.09
Cases in MM

Located at Khurda District, near Bhubaneswar,

Production Volume
16.10

15
11.09

10

9.58

5
0
2010

Production

2011

2012
Year

2013

Policies & Objectives

We at Hindustan Coca-Cola Beverages Private Limited (Company) believe that our people are our most
valuable asset. Providing a safe and healthy working environment is one of our primary responsibilities and
is fundamental to our success. This belief is part of our culture, and the Occupational Safety and Health
(OSH) Policy applies across all our operations.
We endeavour to conduct our business with the goal of zero work-related injuries for our Associates and
business partners present at our workplace. We will strive to improve workplace safety and health by
engaging with our Associates and adhering to applicable requirements of the law and The Coca-Cola
Company, Atlanta, USA (TCCC) relating to OSH. We also believe that it is the responsibility of each
Associate to ensure compliance with the OSH Policy and programs.
In fulfilling this responsibility, we are committed to 1. Establish the Cluster/Area Safety Councils and Factory Safety Councils under the leadership and
supervision of the Apex Safety Council at Corporate and regularly review our OSH Policy, objectives &
metrics for effective implementation & continual improvement of Safety Management System.
2. Establish and maintain programs to ensure compliance with more stringent of legal requirements and
those of TCCC requirements relating to OSH.
3. Ensure the provision of resources necessary to achieve our OSH objectives; and foster continual
improvement in OSH performance.
4. Proactively seek to identify, assess and control OSH risks related to our operations.
5. Provide clearly defined roles and responsibilities, training, communication systems and participation
opportunities to promote effective engagement by Associates at each level.
6. Manage OSH incidents in a manner that protects our Associates, assets, business partners and the
public, as well as the image and trademarks of TCCC, consistent with applicable legal requirements.
7. Integrate OSH in business plans, results, performance reviews and other business routines.
We, at Hindustan Coca-Cola Beverages Private Limited hereby adopt our OSH Policy, which shall be made available to
all Associates. The Apex Safety Council is hereby entrusted with the responsibility of implementing our OSH Policy
using our Safety Principles.
T. Krishna kumar
Achieve Safety Excellence through Behaviour Change

Occupational Safety & Health Policy

Leadership Commitment on safety principle:

In fulfilling this responsibility, we are committed to

1. Establish the Zone/Area Safety Councils and Factory Safety Councils under the leadership and
supervision of the Apex Safety Council at Corporate and regularly review our OSH Policy, objectives &
metrics for effective implementation & continual improvement of Safety Management System.

2. Establish and maintain programs to ensure compliance with more stringent of legal requirements
and those of TCCC requirements relating to OSH.

3. Ensure the provision of resources necessary to achieve our OSH objectives; and foster continual
improvement in OSH performance.

4. Proactively seek to identify, assess and control OSH risks related to our operations.

5. Provide clearly defined roles and responsibilities, training, communication systems and
participation opportunities to promote effective engagement by Associates at each level.

6. Manage OSH incidents in a manner that protects our Associates, assets, business partners and the
public, as well as the image and trademarks of TCCC, consistent with applicable legal requirements.
7. Integrate OSH in business plans, results, performance reviews and other business routines.

Road Safety Guidelines

Mandatory Safety Norms Cardinal Rules

1. Job specific safety induction at gate - for All (TVs have been provided to brief
hazards and protection of people). Strong Gate ACCESS Control.
2. Marshaling of Truck and Forklift inside plant and depots. Better supervision of
Shipping Operations (70% of temporary labor is in shipping operations where
maximum FLT & Truck movements happen)
3. Mandatory Conformance to safe Permit to Work (PTW). All hot work, confined
space, HT electrical, Roof work etc. comes as part of PTW.
4. Mandatory Safety Clause Insertion in all Contract Agreements. This insures
responsibility of 'labor' at HCCBPL site - in hands of contractors
5. Mandatory Defensive Driving Training for all Associates, Drivers, FLT drivers,
2W & 4W users. Mandatory use of Helmets for 2 W and Seatbelts in 4W
6. Mandatory use of Machine Interlocks - and no bypassing of the same
7. Mandatory Use of PPE - Safety Shoes for all, cut-resistant gloves & goggles for
Glass handling and Helmets for working above 8 FT (especially on top of trucks)
8. Weekly 'Leadership Safety Walks' at Plants and Depots and not to walk past an
Unsafe Act.

Occupational Health Policy

We at Hindustan Coca-Cola Beverages Pvt. Ltd, Khurda produce and deliver our
products and provide services with a goal of zero work related injuries and illnesses

for our employees, contractors and all others who came to our plant. Occupational
Health and Safety is one of our highest priorities and we believe that people are our
most valuable asset. We take our responsibility for providing a safe and healthy

working environment and minimizing risks to employees, contractors, and others

seriously. Fulfilling its responsibility is fundamental to the success of our business.

Environment Management Policy

We, at HCCBPL, Khurda ensure a healthy and sustainable environment while protecting and preserving the
environment and reducing environmental footprints through effective implementation of Environment Management
System complying to all applicable statutory and regulatory requirements with active engagement of all the
employees.
TOWARDS THIS POLICY, WE SHALL ENDEAVOR TO ADOPT THE FOLLOWING STRATERGIES

1.

Conservation of natural resources specifically in water by continually improving its usage and reducing wastage.

2.

We ensure the minimal emission of carbon to the environment.

3.

We shall maintain sustainable packaging through recycling of PET bottles.

4.

We formulate environmental objectives and targets and integrate a continuous process reviewing all essential elements.

5.

We ensure proper infrastructure and resources for continual improvement in environmental performances.

6.

The company maintains its commitment to follow and comply all applicable statutory, regulatory and TCCC requirements.

7.

Identifying and evaluating all possible environmental risks and taking corrective actions to mitigate those risks and ensuring compliance with TCCC
and applicable legal requirements.

8.

We prepare for potential emergencies mitigation programs to protect our associates,contractors,customers and public and prevent property losses

and business interruptions.

9.

We strive to consistently improve the capability of our workforce to perform their jobs effectively by providing proper training and awareness and
effective communication system and a dedicated core team with defined roles and responsibilities ensures effective implementation of Environment
Management System.

10.

The company ensures to take stewardship initiatives with public and private entities with collaboration to governments, on-governmental organizations
and others through corporate social responsibility programs to improve environmental aspects of the community.

Journey of Safety Excellence

Our Journey of safety excellence towards the objective with at least
one focus point on year by year

2010:
Low- Safety
awareness /
culture and
safety Infra

2011:
Initial
Transformation
phase- Acceptance
of safety aspects
and initiatives

2012:
Recognize safety as
a part of daily
operation
/ job, building Safety
awareness / culture

2013:
Ownership culture
development and
Audit by safety
personnel

Raising Mass Awareness through

engagement / Campaign / training
Implementing Safety Best Practices
( Elements of TSI- Leading Indicator)
Safety Hardware /Infra correction /
Audits
Safety own by the process owner with
TPM

Achieve Safety Excellence through Behaviour Change

Policies Deployment & Review System

Apex Safety Committee- At Corporate
(Comprising of CEO, Sr. VP- Operations, Sr. VP- Supply Chain, Sr. VP- HR, AVP-Safety VPSupply chain, VP-RTM)

Zonal Safety Committee

(ZVP/ZSCM of the zone along with respective Factory Managers, RTM Head(s) or Unit,
Zone, zonal Safety manager, zonal Distribution Manager, Zonal HR Head,)

Factory Safety Committee

(Factory Manager, Factory Shipping Manager, Factory Production Manager, Factory Quality
Manager, Factory Safety Executive/manager Factory Maintenance Manager, Operators)

Safety Circles

CMC

DMC

(Team Leaders,
Executives, Operators &
Technicians)

(Regular Contractor,
Engineering
Contractor, Project)

Transport Drivers

Achieve Safety Excellence through Behaviour Change

Objectives and Performance

(Water Neutrality)

Achieve Safety Excellence through Behaviour Change

Element of Total Safety Index (TSI)-2013

Cultural

Leadership Walk-Safety Gemba Tours by Leaders

Frontline Participation-Plant Safety Meeting and Tool Box talks
Contractor Safety Management
Proactive Incident Management

Critical Safety Project Establishment

HIRA & Operational Control of Critical Equipment
EHS Software usage for Data Reporting
Managem RED BOOK Compliance
Cardinal rule Compliance
ent
Environment Assurance process
New Parameter added
Jan `2013

100.0
80.0
Actual

60.0

60

40.0
20.0

80

70

41.0

51.0

62.5

66.0

65.0

67.0

71.0

75.0

83.0

84.0

88.0

83.0

0.0

Culture

4.5
3.8

6.0
4.5

5.4
7.5

7.5
5.8

7.5
6.0

Management System
7.3
6.3

7.5

6.8

7.5 7.5

Achieve Safety Excellence through Behaviour Change

9.3

7.7

9.3
7.8

9.5
8.3

9.0
7.8

Leadership Gemba Walk

Lead by Factory
Manager
Schedule at
Thursday of every
week
All HODs
mandatory to
participate
Minimum 5 Person
must be present

Tracking of
Attendance

Tracking of Findings
and Mitigation
Every week
Compliance present
in weekly review

Gemba Walk

Tool Box Talk

Make Calendar
for TBT

S# Date

Quality

1 7-Dec-13 Defensive Driving

2 9-Dec-13 House Keeping
Portable Fire
Extinguishers
4 11-Dec-13 Safety Policy
5 13-Dec-13 Dealing With Spills

3 10-Dec-13

Nominate Circle
leader from
each Circle
Started
Compliance
Measurement
by width &
Depth
Safety person
participate in
one TBT daily
Collect the
suggestion
given by
members
Audit by safety
Manager for
checking
involvement

6 16-Dec-13 Safety Awareness

7 18-Dec-13 Safe Work Habits
What is Confined
8 20-Dec-13
Space?

Shipping

Production-1

Production-2

Maintenance

Stores

CMC

Rest All

Defensive Driving

Defensive Driving

Defensive Driving

Defensive Driving

Defensive Driving

Defensive Driving

Defensive Driving

House Keeping
Portable Fire
Extinguishers
Safety Policy

House Keeping
Portable Fire
Extinguishers
Safety Policy

House Keeping
Portable Fire
Extinguishers
Safety Policy

House Keeping
Portable Fire
Extinguishers
Safety Policy

House Keeping
Portable Fire
Extinguishers
Safety Policy

House Keeping
Portable Fire
Extinguishers
Safety Policy

House Keeping
Portable Fire
Extinguishers
Safety Policy

Dealing With Spills

Dealing With Spills

Dealing With Spills

Dealing With Spills

Dealing With Spills

Dealing With Spills

Dealing With Spills

Safety Awareness

Safety Awareness

Safety Awareness

Safety Awareness

Safety Awareness

Safety Awareness

Safety Awareness

Safe Work Habits

What is Confined
Space?

Safe Work Habits

What is Confined
Space?

Safe Work Habits

What is Confined
Space?

Safe Work Habits

What is Confined
Space?

Safe Work Habits

What is Confined
Space?

Safe Work Habits

What is Confined
Space?

Safe Work Habits

What is Confined
Space?

9 26-Dec-13

Hazard Communication Hazard Communication Hazard Communication Hazard Communication Hazard Communication Hazard Communication Hazard Communication Hazard Communication
on Chemical Safety on Chemical Safety on Chemical Safety on Chemical Safety on Chemical Safety on Chemical Safety on Chemical Safety on Chemical Safety

10 30-Dec-13

Why Safety is
important?

Why Safety is
important?

Why Safety is
important?

Why Safety is
important?

Why Safety is
important?

Why Safety is
important?

Why Safety is
important?

Why Safety is
important?

Dec-13
Width Depth
No of
No of person
Department Owner
Area
Topic covered
QA
B B Panda
10
29.00%
Tetra
8
43.00%
T R Seshu RGB
9
34.00%
PET-140 10
100.00%
Production
Kinley
10
68.00%
B.warlu Krones
10
100.00%
Maaza
8
46.00%
Sampat
Maintenance
10
37.00%
Arul
Shipping
M N Nayak
10
67.00%
Store
N K samal
10
100.00%

12.0

10

10.0

9.0 9.0 9.0 9.0

8.0

8.0
6.0

7.0 7.0 7.0

7.0 7.0

5.0 5.0

4.0
2.0

0.0

Actual

Target

Safety Committee Meeting status

Safety Committee Meeting

Month
Date

Jan-13
Feb-13
Mar-13
Apr-13
May-13
Jun-13
Jul-13
Aug-13
Sep-13
Oct-13
Nov-13
Dec-13
18-Jan-13 7-Feb-13 7-Mar-13 3-Apr-13 8-May-13 5-Jun-13 3-Jul-13 7-Aug-13 4-Sep-13 9-Oct-13 6-Nov-13 4-Dec-13

Status

Point Suggested
Points Closed
% Compliance

8
7
87.5%

a
8
8
100.0%

a
7
7
100.0%

a
8
5
62.5%

a
7
5
71.4%

a
9
9
100.0%

a
8
5
62.5%

a
9
7
77.8%

a
9
6
66.7%

a
6
6
100.0%

6
2
33.3%

6
5
83.3%

Total

91
72
79.1%

Safety Signage's and Hazard Communication

Identify
requirements as
per std.
requirements

Design standard
signage's

Fixed at
prominent place

Ensure
compliance
through Gemba
walk
Review the
requirement best
on suggestion of
associates as
well as yearly

PPE Compliance Trend

Finalize the PPE
requirement from
individual department.

Compile and follow up

from Procurement
dept.. For availability.

Distributed among all

Contractor through
HR.

PPE Compliance

Target

100.00% 98.52%
98.19%
97.90%
97.32%
98.00%
94.11% 94.46%
93.94%95.60%95.92%
95.01%
96.00%
94.50%
93.53%
94.00%
92.00%
90.00%
90%
88.00%
86.00%
84.00%

Made excel sheet for

tracking of Issued Qty

Weekly PPE Stock

circulated by store in
charge

120.00

100.00
80.00

Run Campaign
on Hand gloves
& ear plug use

% PPE Compliance
100.00

100.00

100.00

95.00

93.00

86.10

85.80

74.10

60.00

Started Compliance
Measurement across
3 shift with standard
format
Review the
compliance status
and action plan on
monthly meeting

40.00
20.00
0.00

% Compliance

Incident Trend Analysis and CAPA

Cut resistance gloves mandatory at Glass line

PPE Audit Daily
Tracking of PPE availability
Tool Box talk- Daily
Access Control
Man- Machine Segregation

Contractor Management
Contractor
Management center
where we provide Job
specific Training

SOP developed from

corporate

Engaged standard 3rd

party

Make Infra for Fulfill

requirements
Daily Safety School
running with contractor
supervisor

Contractor Safety Induction AV

started at Gate in multi language

Tool box talk done by

supervisor across 3 shift
Various data trackingPTW, PPE compliance,
Equipment checking
etc.
Review daily, fortnightly
and Monthly

Tool Box Talk

Daily Safety pledge

Audit monthly by Safety

Manager

Reward &
Recognitions

Monthly Review with all participants

CMC- Surveillance
Top 3 Contractor
-Jaganath Electrical
- Anita Fabricators
- Paul engineering

Bottom 3 Contractor
- Gear
- Quality Facility
- Maa Bateswari

Rewarded for the best contractor for

the Year-2012 through Factory
Inspector

Benefits
Description

2012

2013

% Reduction

Total No of Injury

117

36

69%

No of Injury- Contractor

74

18

76%

No of Injury Employee

43

18

58%

2012

2013

117
120
100
80
60
40
20
0

Over all Injury

Reduced by
69%

74
36

Total No of Injury

G
O
O
D

43
18

18

No of InjuryContractor

No of Injury
Employee

Safety Health & Environment

Hazard Identification and Risk Assessment

Achieve Safety Excellence through Behaviour Change

Awareness Training and Mock Drill

Achieve Safety Excellence through Behaviour Change

Driver Management Center -Process

Unsafe
Driver

DMC
Zero
Incidents
Unable to
Manage
Road Risks

Unsafe
Vehicle

Explain Journey Risks

Any personal problems effecting his
driving ability
Explain HCCBPL Violation Policy
Explain emergency contacts and
accident reporting procedure
Discuss Road Worthiness

Alcohol Test if suspect

DMC - Pre-trip Counseling

Explain Journey Risks

Post Trip Counseling

Route Adherence

Continuous driving
Any personal problems
effecting his driving ability
Breakdown
Explain HCCBPL Violation
Policy

Explain emergency
contacts and accident
reporting procedure

Physical condition of driver

Rest allowance

Vehicle familiarity
Discuss Road Worthiness
Turnaround Time
Alcohol Test if suspect

Discuss GPS report

Observation once available
Explain Safety precaution
for truck movement within
the plant

Journey route risk assessment

Occupational Health Management

Occupational Health Process For Employees
Coca-Cola Associate
Pre Medical Check-Up
Job specific Induction
Area related Health
measures
Annual Health Check-Up

Awareness camps

Achieve Safety Excellence through Behaviour Change

FORKLIFT
BATTERY
CHARGING ROOM

Zone Mapping regarding Health Hazards

DRIVER REST
ROOM

Health
Hazard

FORKLIFT
MAINTAINANCE
AREA

RAIN WATER HARVESTING PITS

USED PULP
DRUMS

STORE
CIP
ROOM

PULP STORAGE AREA

PULP

OPEN YARD
LPG STORE

ETP
STORE

VERMI

DRY BASE

CROWN
STORAGE

ETP LAB

COLLECTION
TANK

KRONES
FILLING
HALL

HAZ WASTE
STORE

HCL
STORAGE
TANK

EMPTIES YARD

EAP

CIP ROOM
TETRAPAK CHILLER

RAW
SYRUP
ROOM

AC STORE

KW
FILIINING
HALL

PET FILLING
ROOM

KW Blowing Room

BLOWER -2

CARTON
ROOM

Blower-1

WARMER & LABELLER

READY SYRUP ROOM

CSD PACKAGING HALL

CSD PACKAGING HALL

CSD FILLING ROOM

CHILLING PLANT

CAUSTIC YARD

SHIPPING
OFFICE

QA LAB
PROD. OFFICE

CONC. STORE

WTP CHEM
STORE

CROWN STORE

RM STORE

TETRAPAK
CANISTER
FILLING ROOM

SAMPLE ROOM

CANISTER CIP
ROOM

LOCKER
ROOM

ADMIN

FA ROOM

NEW WTP

CO2 YARD

UPS ROOM

ADMIN

CMC

LADIES

CROWN STORE

PANEL ROOM

DG
ROOM

RESTROOM

WTP

STORES

WTP
DG PANEL ROOM

WORKSHOP

TRANSFORMER

NEW
DG

FIRE WATER
PUMP HOUSE

PCC ROOM

HSD AND FO YARD

PANEL ROOM

AIR COMPRESOOR

Chemical
Hazard

EMPTY CRATE
LAODING

BOILER ROOM

READY
SYRUP
ROOM

Toxic Gas
Hazard

EMPTY
YARD

LODING AREA

SUGAR GODOWN

BOILER ROOM

MITECO ROOM

PACKING HALL

FG WAREHOUSE

COOLING TOWER

RAW WATER
TANKS

High noise
area

UNLOADING
AREA

DPG

COMPRESSOR ROOM

RAW
WATER
TANK

WATER PUMP
HOUSE

LUBE OIL
AND
MISC
STORAGE

BLOW
MOLDING

KRONES
PACKING AREA

SUGAR GODOWN

DECAUSTICI
SER

FG WARE HOUSE

MAAZA PACKING HALL

Air Comp

ANAEROBIC
TOWER

Maaza
Filling hall

QA LAB

ETP BLOWER

ETP
PROCESS
AREA

SCRAP
ROOM

COMPOSTING

CIP ROOM

ETP
PANEL
ROOM

CULLET WASTE,
GARBAGE<IRON
SCRAP

TRUCK
PARKING
AREA

SLUDGE DRYING BED

CHEMICAL STORAGE
ROOM

UFRO

CONTRACTOR
REST ROOM

STP

Grass Land

HT Yard

CRECHE

Grass Land
CANTEEN

Eye Shower
CO2 Fire extinguishers

Fire Hydrantas

DCP Fire extinguishers

Hazardous Building

M-Foam fire extinguishers

Emergency Exit

Water CO2 fire extinguishers

PPE BOX

Sand Buckets
First Aid Box

Water Monitor

Legends

FOUR WHEELER PARKING ZONE

AMBULANCE

Hazard To Health

Prepared by -N K Dubey

Approved by -Mohan Singh

S
E
C
U
R
I
T
Y

SMOKING
ZONE

EMERGENC
Y
ASSEMBLY
POINT

TWO WHEELER PARKING

ZONE

Medical Tests conducted for Each

Area

Revision Date-16th Jan 2013

Area
Production
Maintenance
Quality Assurance
Shipping
Human Resource
Stores
Procurement

S
E
C
U
R
I
T
Y

Physical Examination
Audiometric Test
Ophthalmic Test
ECG
Blood Test
Urine Test
Eye Test
Pulmonary Function Test

Illumination Study
Before

After

We Study the illumination on monthly basis and based on findings correct it then
and there

Ergonomic Improvement

Ergonomics:
Modify the rejection conveyor for auto drop of rejection- avoid the bending
Change the door position of sugar hoist so manual handling activities of 50
kg bags eliminated
Change the process of caustic ( From Flex to Lie) using in bottle washer to
avoid manual handling
Conveyer extended at Tetra De- Palletizers minimizes physical stress in
job resulting in high productivity levels
Engineering Control- Kaizen to eliminate ergonomic hazard

Before

After
Change the opening side and use Forklift in place of
manual loading

Health Awareness Program

Training on women health

awareness

Blood Donation Camp

Toolbox talks on Health topic

to contractors

Health Check Up Camp

Environment Management

People
Equal Opportunity
Diversity
Outreach Programs
Human Rights

Planet

Profit

Permit and License

Compliance

Consistent Profitable
Growth

Bio Diversity
Emissions to Air
Water / Chemical Usage
& Discharges

Risk Management
Total Shareholder
Return

Environment Management

Environment Approach

Reduce

Reuse

Replenish

Rinse Jet size optimization in Bottle

washer
Optimized water consumption for
Line Lubrication
Optimize CIP Timing for Syrup Tanks
Production planning to optimize
CIPs

Rain Water Harvesting Structures

within Plant and across Community
(Schools, Offices)
Massive Awareness Campaigns
Monthly Water resource
Management Meeting and Gemba
walk
Decaustic Plant Recovery
improvement to 80%
ETP UFRO Water for Utilities
Vacuum Pump Seal cooling Water
Recovery
Back Wash water Recovery
Condensate Recovery Improvement
to 80%
Installation of Anaerobic tower in
ETP

WUR : Identified - Opportunity area

3.5

3.2

Initiation of Vermicomposting

Up gradation
of ETP

2.79

2.5

1.88

2
1.5

1.69

1.6

1.55 1.61 1.45

1
0.5
0

2007 2008 2009 2010 2011 2012 2013 2014

Target

1. 100% utilization of UFRO running

2. Recovery of Treated water (used in
CIP)

1.65
1.60
1.55
1.50
1.45
1.40
1.35

0.07

1.61

1.54

0.06

1.49

0.04

1.45

1.45

3. Kinley Line Loss

Presently Plant is 74% water neutral ,Target is for

200% water positive by 2020.

Action taken for Water usage ratio improvement

Environment Initiatives
Up gradation of ETP : Introduced
fludized bed media system (1000 kg of
BOD / day can be treated)

Commissioning & Successful utilization of

UFRO- to maintain WUR

Installation of oil skimmer & cleaning

activities in collection sump

Commissioning & Successful utilization of

Centrifuge for proper handling of sludge

Improvement in sludge drying bed and protect the

beds via plastic sheets from external factors

Fish Pond

Contribution towards Environment

PCB Compliance To Waste Water

9
9
8
8
7
7
6
6
5

8
8
8

JAN

pH

8
88

FEB

8
8
8

MAR

7
7
7

APR

8
7
7

MAY

8
8
8

JUN

110

8
6

JUL

AUG

SEP

8
7

8
87

8
8

88

8.5
2011
2012

6.5
OCT

NOV

DEC

2013
Target

TSS

90

<100

70

52

50

32 27
24

30

36
26 21

22

48
27

54
24

2011

30
21 18

22 20

21
16

22
15

AUG

SEP

33
28

29
16

15

28
29
18

2012
2013

10
JAN

FEB

35

28

30
25
20

MAR

22
20
18

24
17

APR

MAY

JUN

JUL

BOD
26

15

14

11

19
18

15
12
11

13
12

JUN

JUL

NOV

DEC

Target

28

26
20

16

OCT

17

14
11

13
9

AUG

SEP

OCT

NOV

10

22
19
17<30

2011
2012
2013

5
JAN

FEB

MAR

APR

MAY

DEC
Target

PCB Compliance To Waste Water

10
9
8
7
6
5
4
3
2
1

2011

4
3
2

JAN

240
220
200
180
160
140
120
100
80
60
40
20

<10

OIL & GREASE

3
3
2

FEB

3
2
1

MAR

APR

3
22
MAY

33

4
3

4
3

2012
2013

2
1

Target

JUN

JUL

AUG

SEP

OCT

NOV

DEC

<250

COD

90

100

2011
86

82

84

54
35

52
31

39

36

52
34

JAN

FEB

MAR

APR

MAY

65
38 42
JUN

46
41
32

36

38
33

46
52
31

JUL

AUG

SEP

OCT

54

42

50
30

52
37

NOV

DEC

2012
2013

Target

PET Recycling

Contribution towards
environment

ZERO LANDFILL WASTE Zero waste sent for landfill, all

non hazardous solid wastes recycled / co-processed.

Now machines at Khurda have life

Dancing doll gives alarm when
water level low in 2T boiler

Dancing doll gives alarm when

safety door is opened in RGB
CSD line

Energy Management

Standard KWH sheet

Power tracking sheet

Energy saving kaizens

Energy Saving Kaizens

Power-Factor improvement
Boundary Light Automation
PCC-2 auto synchronisation

PCC-1 & 2
interconnection

69 Energy
saving Kaizens
have been
implemented

Energy Saving Kaizens in PET CSD 600 BPM Filler

AFTER

BEFORE
CHILLER

CHILLER

SECONDARY
PUMP

SECONDARY
PUMP

120 KWH
savings

COLD
WELL
HOT
WELL

COLD
WELL
HOT
WELL
PHE
PHE

NO PRODUCTION
NO PRODUCTION
FILLER

MIXTURE
FILLER

MIXTURE

Volume in Lacs
61.61

27.2
30.89

28.3

30.9

67.01

73.08

74.27

Investment of
12000

7.2

6.2

4.02

6.6
Dec-13

Jul-13

Jun-13

May-13

Apr-13

Mar-13

Feb-13

Jan-13

7.6

1.80

Nov-13

9.6

Month

75.01

74.82

74.52

32.4

8.9

0.53

72.66

Oct-13

6.8

46.69

Cummulative Savings in Lacs

Sep-13

80.0
70.0
60.0
50.0
40.0
30.0
20.0
10.0
0.0

Aug-13

Saving in Lacs

Energy Management Achievements

Cumulative Cost Saving due to Energy Saving Kaizens

Sustenance Tool of the Implementation Systems

ROUTINES

Developed Routines @ all

Levels.

All Leading indicators 5S,

BEC, PM & CI is part of Daily
Routines.

Factory DMS

Daily DMS @ 11: 00 am will be

carried out by F.M along with
process owners on daily basis
covering QSPECS.

Alignment of Expectations.

Common approach on
Achieving Business goals.
QSPECS

Common approach on
Achieving Business goals.
QSPECS

Monitoring & control made

more effective

ROUTINES

Factory DMS

Classified - Internal use

Shop Floor DMS

Shop Floor DMS will be carried out at

beginning of Every Shift involving
operating Team.

Interactive session on Shift

Performance, Routines Compliance &
Pending works.

Effective Upward Down ward

Communication.

Involvement of operators in Gap

Analysis for immediate corrections.

Shop floor DMS

12.2 CORPORATE SOCIAL RESPONSIBILITY

Coca-Cola SUPPORT MY SCHOOL

Total 74 % water recharged to

ground

Pond before Renovation by HCCBPL

Total 22 water recharge facility

created out side the plant

Achieve Safety Excellence through Behaviour Change

Model Village Project

96% population belongs to Scheduled Tribe

Category
Lowest Literacy rate among nearby villages
High level of poverty (Low Income mostly daily
wage earner -89%)
84 % having only Thatched houses
Absence of basic requirements of Toilet in
households, open area used

Model Village Project - access to health, safe drinking

water, sanitation and education and overall Quality of life
thru self sustaining livelihood projects in 02 villages
Bada Sabar Sahi and Sabar Sahi (SC & ST village).

Access to Health and Sanitation

Drinking Water

Support for Education

Livelihood Support through SHGs 11-14 women in

each of 5 SHGs operating

Support for
Education

Drinking Water

Safety Day celebration

Environmental Day Celebration

Glimpse of Member Secretary, PCB - Odisha & Team 26th

May `13

Award & Recognition

Coca Cola Quality
System Award - 2001

Max Glass Program

Winner - 2003

Max Glass Award of the

Year 2003, HCCBPL
Khurda

Coca Cola Quality

System Award - 2003

Pollution Control
Excellence award 2005

State Pollution Control

Board Orissa,
Bhubaneswar,
Pollution Control
Excellence award - 2005

CCI Bottler Excellence

Award
Highest Score in
production Rating - 2006

State safety Award

2006
Lowest Severity Rate of
Accident

Excellence in HR ,2007
Orissa
Central Champions
Confrence ,2007

Quality Environment
and safety
Occupational Health
award - 2008

Recognitions
CII National Award
for Food Safety -2013

Best Kaizen award for

"Supervisor-Manager Level
category". 2013

Quality Environment
and safety Occupational
Health award - 2008

Gold certificate of Merit - The

Economic Times Indian
Manufacturing Excellence Award

State safety Award

Lowest Severity Rate
of Accident-2006

Odisha State Food

Safety Award 2012

State Pollution Control

Board Orissa, Pollution
Control Excellence
award - 2005

Award & Recognition

Integrated Supply Chain

Meet
November 2009 Goa
Best WRM Central
Region, Bhubaneswar

Best Growth in Sparkling Category

2009
Best Performance on RTM score
2009
Best Growth in juice category - 2009

Best Unit in HR Costs /

Productivity 2009
HCCBPL, Central Region ,
HR Meet -2010

Best Factory of the Year - 2011

Max Glass award - 2011

Award & Recognition

Safety award 2012 Excellence in
Man Machine Segregation

Odisha State Food Safety

Award 2012

CII JIPM award for "Supervisor

- Manager Level Kaizen"

Supply Chain Seasonal Award - Max PET- High Speed PET(>=430 BPM)

Recent Honor
Khurda Plant has been awarded with
Odisha State Food Safety Award
2012. The award was given by our
Honorable the Chief Minister of
Odisha Mr. Naveen Patnaik on 15th
Feb 2013.

Classified - Internal use

Recent Honor
Khurda WON the CII JIPM award for "Supervisor-Manager Level Kaizen"

Classified - Internal use

Award & Recognition

The Economic Times India Manufacturing Excellence
Award - 2013

The ET IMEA, Frost & Sullivan

Gold Certificate of Merit

8th National Food Safety & Quality Summit - 2013

Confederation of Indian Industries (CII) - New

Delhi (3rd 4th December2013)