Nestle Summer Associate

Program-2014

Umar Saeed (Industrial & Manufacturing Engg, UET, Lahore)

Department: Engineering

M. Zubair Amjad Project Engineer

Nestle, SKP-factory

Zeeshan Ameen Senior Project Engineer

Nestle, SKP-factory

LINE Managers:

Acknowledgements:

I dedicate my accomplishments during

this internship to my line managers Mr.

Zubair Amjad & Mr. Zeeshan Ameen.

Their sincere guidance & complete

follow-through supported me to achieve

my tasks in such a short time.

Engineering Dept. overview

Utilities

Maintenance --Boilers

--Refrigeration Equipment

--Electrical Gen. sets

Capital investment

projects -- New Installation of

lines, plant machinery etc.

Utilities Projects -- Installation of boilers,

chillers, compressor

room etc.

Engineering

Department

Projects during Internship:

-- Designed the best possible layout for yogurt plant old blast for the installation of cooling cells, calculating costs and energy savings and calculation of payback period.

-- Formulated a project plan w.r.t. time estimation of sprinklers installation in warehouse 2 & 3 using MS-Project.

-- Calculation of cooling load of Tetra Hall using ACCALC, comparing with A.H.U. capacity before and after installation of ELPO & Prisma line and proposed an optimum solution.

-- Study & optimization of CIP target lines for readjustment to reduce downtime on highly loaded lines & make room for new targets.

-- Planning of activities for dismantling, shifting and installation of Duplex filling from Egron-2 to Egron-1.

1st Project

Objective: Reduction in down time by shuffling

targets.

proposal for adjustment of new targets.

Duration: 24th June - 24th July

Area: Standardization

Study & optimization of CIP target lines for readjustment to reduce

downtime on highly loaded lines & make room for new targets.

Time load on lines

Line 1 12hr 50min

Line 2 7hr 20min

Line 3 10hr 55min

Line 4 10hr 10min

Line 5 9hr

Results: Proposed plan for CIP distribution on

discussion with staff persons and made

CIP distribution diagrams for all existing

lines after addition of new targets.

2nd Project:

Objective: Calculate the cooling load.

Comparison with existing A.H.U.

Provide optimum solution if its under

capacity.

Duration: 30th June - 10th July

Area: Milk Standardization

Calculation of cooling load of Tetra Hall using ACCALC, comparing with

A.H.U. capacity before and after installation of ELPO & Prisma line and

proposed an optimum solution.

Results: Cooling load by ACCALC = 894 kW

A.H.U. Capacity = 888 kW

Difference = 6 kW

Solution: Re-designing of cooling

coil, it’s efficiency can be increased

by 30%.

Summarized data from ACCALC:

Scope Media

AHU Nestlé Star-Rating 3-Star

Coarse filter class G4

Fine filter class F7

Cooling coil yes chilled water 7 °C / 13 °C

(re)heating coil yes steam 3 bar

supply airflow 118,000 m3/h

outside airflow 9,040 m3/h

outside air conditions summer 45.0 degC 85 %rH

return air conditions summer 30.0 degC 50 %rH

supply air conditions summer 19.4 degC 13.7 g/kg

(re)heater temperature in/out 18.2 degC 28.9 degC

3rd Project:

Objective: Layout optimization of Blast Room for

installation of cooling cell.

Calculation of energy & cost savings.

Group Member: Amna Nawaz

Duration: 11th July - 22nd July

Area: Yogurt Plant

Designed the finest layout for yogurt plant old blast for the installation of cooling

cells, calculating costs and energy savings and calculation of payback period.

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4th Project:

Objective: Project planning.

Adjustment of activities with working

movements in warehouse.

Duration: 10th July - 16th July

Area: Warehouse 2 & 3

Formulate a project plan w.r.t. time estimation of fire sprinklers

installation in central warehouse using MS-Project.

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art

Result: Time for completion

is 2 months & 10 days

5th Project:

Objective: Turn out the constraint of time during

annual shutdown.

Decision of resources and man hours

Make a project plan.

Duration: 21st July - 5th August

Area: Egron 1 & 2

Study & Planning of activities for dismantling, shifting and

installation of Duplex filling from Egron-2 to Egron-1.

Results: Completion in 9 days before deadline

Man hours = 207

Working days = 27

Summarized Conclusions:

If your project is designed perfectly in the planning phase

and initial stages then, situation go well in your favor.

Don’t hesitate to ask, more you ask less mistakes you

make.

Don’t rely on other’s calculation. Do them yourself.

No one else can be blamed, only you’ll be the responsible

for not meeting your targets.

Other Activities:

Visited MRU and got an overview over whole milk

receiving process and then its initial processing

before pasteurization

Checked the feasibility of replacing THE with PHE & PHE with THE in skp-

factory on basis of discussion with plant

manager

Got summary of the whole yogurt formation

process from raw material in milk form to

final processed product.

Understood the working of filling machine in Tetra

hall from a worker operating that machine.

Visited technical storage and learned about how inventory is managed according to required

demand

Performed Vacuum pressure test on the compressors of the

cooling units in cold blast

Visited “pure life” water plant and got an

overview over whole process of blowing,

filling, packaging etc.

Received an overview over waste water

treatment plant by visiting it and understand the

whole process

Went to see E1 & E2, checked out the process of powder formation & some other technical

information about plant

During discussions, understood the process of P2P that involves the

steps involving from purchase order to

receiving

Made a tour of chillers for chilled water formation and cooling towers and

understood their working

Studied some data relating to Wartsila,

boilers, refrigerating units , A.H.U. etc.

Suggestions on common observation in

Nestle

About Plant

Preventive Maintenance

Proper examination of pipes

insulation

Follow standards using

hook-up plates

Shift to automation as much

as possible

Minimize heat loses in

areas under A.H.U.

About Management

Try to shift towards pull

system from push system

Job rotations & jobs in

accordance to employees

background

Defined areas for persons

with same jobs in office.

Unannounced visits of SHE

and 5’S teams

Suggestions on common observation in

Nestle

About Safety

Proper use of hygiene

cap.

Use of Masks in CIP

tanks room.

Sign boards to direct

towards walking surfaces.

About Associate Program

Try to create a competitive

environment among them.

Allocate depts. according to

area of interest.

Defined projects list by each

line-manager before start of

associate program.

Treat them like permanent

employees.

Special Thanks To:

Ghufranullah Khan Business Support

Executive Engineering dept

Maratib Ali Manufacturing

Specialist STD

Saeed Mughal Shift Engineer Yogurt Plant

Ikram Yousaf

Karam Elahi Team Leader Yogurt Plant

Shakir Hussain Ammonia safety

champion Engineering Dept.

Mohammad Mobashir Project Engineer Engineering Dept.

Asif Siddiqui Draftsman Engineering Dept.

Line-Managers Feedback:

“You are keen to learn, not hesitant to work on sites and possess good

analytical skills but you should need to improve your communication skills and

be confident on your work. I wish you to groom yourself to such an extent of

being stated as a true Muslim and the most demanding employee.”

(M. Zubair Amjad)

“In your interaction and task-orientation with me during projects, I found you

motivated, hardworking and intelligent. Try to avoid pillow talk in your

communications and I wish you to professionally grow to the highest level in

your career.”

(Zeeshan Ameen)