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Greaves Brewery

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Sohan Phal Dessai | Sec B | 2012112

Greaves Brewery: Case Analysis
Abstract: Greaves Brewery enjoyed an excellent reputation as a maker of beer that had won both local drinkers and tourists who chanced to try out its bottled product during their trips. Located in Trinidad, a southern Caribbean island, Greaves Brewery was established in 1924 by John Greaves, its founder. Through the years, Greaves Brewery had steadily grown and eventually began to tap the export markets as well. The company reaped its highest level of sales in February 1991. The increased demand for Greaves beer called for prompt action for the company to improve its production operations to keep up with the favourable development. Issues of the Case: In the course of finalizing the design for an additional bottling line for Greaves Brewery , the company’s chief engineer , Lesley Simpson , had to decide on issues pertaining to how the bottled beer in cases should be placed on the pallets . The company was currently using manual labour for this part of the production line. Meanwhile, there is the available option to set up an automated system for it.

Problem Statement:  Increasing capacity to 1000 bottles/minute to meet increasing peak sales demands 4 times a year; Carnival (Feb), Easter (April), Independence Day (August), Christmas (December). Highest sales were during carnival. Material Handling is a problem so the manager is considering of setting up a automatic palletizer.



The Bottling Process:     Bottling plant and warehouse part of same building, but were separated by a wire fences. Current bottling capacity was 400 bottles per minute. Periodic time operation resulted in 85% durational running Past three months were running at 3 shifts per day. This was cutting into the maintenance time.

Sohan Phal Dessai | Sec B | 2012112      Third shift was difficult to staff and supervise. This resulted in the opening of a new higher capacity bottling plant. Took around 7 seconds per case, each weighed 32.7 lbs. Two forklifts carried the pallets and the same were stacked 3 high, The level of the stacks were increased during the high production season

Challenges of Setting up New Plant:       New bottling plant consisted of addition 2 packer units. They would load onto the exit conveyors. A new empty bottle conveyor feed in system was planned and would occupy all the existing space between the bottling shop and the warehouse. The cost of additional conveyors and for hand loading pallet system was $ 108000, including installation. This however reduced the distance normally travelled by forklift. The turnaround time was found to be 35 seconds to three minutes. Would normally average 1 minute.

Automatic palletizer:        Looking substituting of the current manual palletizer with and automatic one. Would take 8 cases and stack them on the pallet, based on a predetermined pattern. The pallet was then lowered to the next layer. The full pallet was put onto the discharge conveyor, which could hold up to 3 layers. One operator was required as a watch over the process in case of emergency. Paid $450pm Two parties available: Perrin and Clarke. The palletizer required a different feed system from the manual loading because of the counting operation and machine height. 45 cases per minute operate on 50 Hz supply; load at least 40 cases per pallet and stacking system identical to the present.

Evaluation of two Service providers:

Perrin

Clarke

Equipment Cost Good reputation and Experience Good Reputation Light, easy to install and durable, efficient Bulky, heavier and more difficult to install Ready convertibility of all conveyors to any of No particular advantage the three basic types, live roller, gravity, or belt type

Sohan Phal Dessai | Sec B | 2012112
Machine is mechanical with gears, belts etc. and Hydraulic with few mechanical parts BUT 12 foot would not require any foundation hole in the ground to lift the pallet piston It would require an air-line with a pressure of The air pressure line on the shop floor was 120 psi. & Additional compressor ($2400 enough. Total cost $324000 Price $ 408000 Installation Cost Traffic control unit $72000 Control unit $72000 Conveyors $60000 Conveyors $48000 Installation cost $108000 Total cost $240000 Installation cost $90000 Total cost $210000

  

Mechanics handling the bottling plant repairs @ $540 would be trained to handle the palletizer. Both run on electricity drawn from the bottling plant. Each had a 12.5 HP motor and would cost $4500 a year.

Submitted By:Sohan Phal Dessai Section:-B Roll no:-2012112 PGP1

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