Rapport de stage Production - Free42qi.free.fr/Perso/Rapport de stage Heineken en Anglais.docx · Web viewInternship Report Company: Heineken Introduction Heineken is a company that

2008

Alexandre TorresaniSupméca Paris20/03/2008

Internship Report

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Torresani 20/03/08Alexandre

Internship ReportCompany: Heineken

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IntroductionHeineken is a company that employs about 1400 people in France, through its 4 plants, 3 of them in the north, one at Mons-en-Baroeul (Lille), two in Chiltigiem (Alsace), and one in the south, in Marseille. Marseille’s factory employs about 130 people, and runs almost 24/24 to serve a large part of southern France. The site has an area of 12 hectares, and sees transit each day dozens of semi-trailer providing bottles or drums for clients.

Despite its name, Heineken breweries, do not produce only Heineken beer, but also produce 33Export, Panach 'and Monaco. Its annual production capacity is 1 million hectolitres.

It should be noted also that a lot of machines just have been changed when I have started my internship. In other words, almost all the machinery has been dismantled. A party was sent to the scrap yard, and another reorganized. However, installation, setup, training workers takes time, which means that the factory is at idle since December. The return to "normal" is scheduled for the month of April. But it has had positive aspects for me because I was able to be self-sufficient quickly without having the pressure on the speed of the chain. And it's also when there are problems that we see each part of the chain in detail and how each link can paralyze the rest.

Obviously, as in any factory, the security conditions are important to prevent accidents as much as possible because the broken glass is very common and the machines run quickly. It is mandatory to wear in the working area, individual safety equipments:

- Gloves - Glasses - Safety Shoes - Earplugs

The Marseille Heineken breweries produce about 2 million bottles and 10 000 barrels per day which is a huge hub for the beer industry in the south of France.

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Internship’s aims

Aims   :

- Understand the work on an industrial chain. - Get an opinion on the work of worker. - Learn more about quality control of the finished product.

Position   :

Packaging operator (bottles)

Vidéomaker being, I made several videos

and recordings to support my report. They

are playful, short and allow instantaneous

understanding of manufacturing

processes

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BREWERY’S DIRECTOR

CHIEF OF QUALITY & PACKAGING

TEAM MANAGER+ Team B TEAM MANAGER

+ Team A

TEAM MANAGER+ Team C

GROUPE FUTSDrum’s team

ADMINISTRATIF

Coordinator TQM Coordinator Technique

SUPPORTS TQM Packaging Laboratory

Company functioning

a- Corporate structure   :

The Heineken breweries have a traditional structure. But the purchase of new machines has led to some changes in the hierarchy, since some posts have appeared / disappeared. There is no specific organizational structure of the company in the current state of affairs.

Organazation

But it was important for me to show all facets of the company and not just the small portion where I worked. Because what I have discovered in this first stage is the interdependence of things in the industry. Each service is dependent on each other, everything is inter-connected and any problem in a place of the factory can paralyze the whole of it.

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b- Beer making   :

a- Raw materials

The beer is made from malted barley. It is barley, which are sprouting leaves, and then we stopped its germination, it said it was malted. In reality during germination, a pocket of enzyme is breakthrough in the grain, which is necessary for the successful completion of beer. This grain is first delivered by truck and stored in huge grain silos.

Malted barley Grain silos

b- Manufacture of flour

Then, the grains pass through a mill where they are crushed .We add hot water to obtain a sweet brown juice.

Mill Tanks

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c- Filtration and control

The sweet juice that comes vats still contains envelopes grains, it should be filtered in order to rid of it. The liquid is transferred into a tank of 700hl where it is filtered. The heavier particles deposited at the bottom. Throughout the process, everything is controlled from the cockpit, where many sensors reflect in real time the status of all tanks.

Tank filtration Cockpit

d- Adding hops

To give a bitter taste in beer we add hops. In the past, it added directly hop flowers, but nowadays it is made from concentrate. We see on the photo below pots concentrated hops: 14kg those used to flavour 700hl of beer. Then, the beer is heated to kill bacteria that are still there.

Hops pots Boiling tanks (700hl)

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e- Fermentation The beer will now be cooled to about 10 ° C and then stored in large tanks (600hl). Then we will add yeast and let it ferment for about 2 weeks. Then we filter yeasts (which largely recycle), and refines the taste the beer by adding so fine and precise hops in order to get a beer that has the same taste. It also adds caramel to give a beautiful colour.

Fermentation tank Filtration of yeasts

f- Storage The beer is now ready to be packaged and it will be stored in an insulated tanks.

Storage tanks (600hl) Referrals

g- My feeling about it I wanted to give my opinion on that part of the factory. There are things which are difficult to teach. The first thing I have notice in this part of the factory is the smell. Unfortunately, it is impossible to report on this, but in the entire area, you can follow the various operations to the smell. We feel that the product evolves gradually changes and moves closer to the smell of beer that we all know. It’s this olfactory morphing that I wanted to highlight because it is really impressive.

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c- Drums

The filling process is very similar to that of the bottles. The empty barrels pallets arriving and drums are washed.

Arrival of empty barrels External cleaning of drums

Then drums will be emptied of beer that remains basically, cleaned with water and then washed. They are then sterilized and filled.

Cleaning / Sterilization / Filling Evacuation

Then drums are stacked by successive layers to make pallets, each of them weighing almost 1 ton. They will be stored while awaiting shipment.

Pallet of drums Storage of pallets

Video (1min30) available: http://tptz.free.fr/Heineken/Vidéo-HK-futs

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d- Bottles

i) Bottles sector   :

ii) Quick description:

Here's a quick description of the chain, starting from its origin.

1-DÉPALETTISEUR: Put empty bottles on the circuit

2-SOUTIREUSE: Cleaning / Filling bottles

3-PASTEURIZATION: Enable the conservation of beer

4-LABELLING: Paste labels on bottles

5-DUODOZEN/BAUMER : Put bottles in pack

6-PALETTISEUR: Put the packages on pallets

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iii) Operating detailed:

1- Dépalettiseur :

This is the first step in the chain, which consists of putting empty bottles on the circuit. The machine but bottles on the conveyor layer by layer.

Pallet of empty bottles

2- Filling :

Empty bottles arrive; they are rinsed with water, sterilized and they are immediately filled and encapsulated. All this in order to limit the exposition of the product to the ambient air.

Machine in work (50 000 bottles/Hour)

Video (2min50) available: http://tptz.free.fr/Heineken/Vidéo-HK-bouteilles

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3- Pasteurization :

After filing, beer is fit for consumption. However, its expiry date is scheduled for two days. To prolong the life of the beer bottle, it must be pasteurized. For this, one solution, the pasteurization. The process is simple, beer is rising in temperature, reaching the 60 ° C and then decreased gradually to 25 ° C. This stage lasts about an hour. On leaving beer is consumable for one year.

Pasteurization

4- Labelling :

During this operation, 3 stickers are pasted on bottles, in order to permit them to be recognizable.

Labelling

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5- Duodozen/Baumer :

This step corresponds to the packaging (packs of bottles). It I was here during my internship. So I will detail this service as a third part.

Packaging

6- Palettiseur :

This is the last step in the chain. It consists of stacked properly on a pallet, packs out of the packaging. The pallets are then evacuated to a hangar where it is stored before being shipped by truck.

Pallet of (3x4 HK) ready to be sendVideo (2min50) available : http://tptz.free.fr/Heineken/Vidéo-HK-bouteilles

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Internship check-up

a- Packaging

i) Work plan   : As in many factories, the work is organized in 3x8h. Thus, the factory produces 24/24, and 3 teams worker / technicians / engineers relay. I quickly been integrated into one of the teams, so I followed the rotation schedule by one week to another. 

These schedules are:

- 5h-13h- 13h-21h- 21h-5h

ii) How work the ‘Mead DUODOZEN’ ?   : I was trained in packaging in a few days, being with another worker who taught me the functioning of the MEAD DUODOZEN.

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The machine, on which I made almost all of my internship, is a machine which can be summarized like this:

Bottles

Packs

Cardboards

It puts bottles in packs, of sizes variable. The size of the packs go from 6 (2x3) to 30 (5x6) bottles.

(YxZ) :

- Y number of rows- Z number of bottles per row

MEAD DUODOZEN

The machine has four parts :

- Cardboards part- Bottles part- Pasting post- Engines

MEAD DUODOZEN

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Cardboard part   :

 Thanks to the suction, cardboard are taken in the store (1) and go into the machine (2). A metal finger keeps the bottom of the pack (3) while others just raise the top of the pack (4-5). Then the pack is caught between two catches and go to the bottles part (6-7-8).

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Cardboard store of DUODOZEN

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Bottles part:

The bottles come by a conveyor. The sensor B30 (swings) can detect a possible broken bottle. The bottles are grouped according to the size of the package (e.g. 3x4), and are driven within the cut by the side of the latter. A star (6) allows you to block bottles when they are pushed to prevent them from falling on the other side. The star (7) allows for its fold in the sides of the pack in preparation for gluing.

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Pasting:

The aim is to close the pack to permit it to keep bottles. The machine deposited on the lower pane 2 or 3 parallel lines of glue, some continuous and others discontinuous. This injection of glue is provided by guns supplied with hot glue via an external device.

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iii) My work   :

1-Fill the store:

My first task was to fill the store with cuts (future packs). It was this action that was most of my working time because it is necessary that the store is always filled to avoid a shutdown for lack.

Cardboard (4x5)

2- Look after the machine:

Sometimes the machine stops to work because the multitude of sensors can obviously stop production as soon as a problem is detected. And so the work of the operator is to identify the source of the problem and solve it as soon as possible.

3- Control packs quality:

The company has developed a system to continuously controlling at all levels of the chain. So every hour, the operator has to take some output and check specific points and fill a table.

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b- Exchanges Company/Student

i) Student Company   :

I have replaced workers who were sick, so I was useful for the company.

My status of trainee has allowed me to collect all points of view (manual / technicians /heads). And it’s very easy to notice that they see problems differently, and gets different way to solve them.

ii) Company Student   :

So I understand better now how the large-scale production of a product is complex to implement and that the slightest mistake at any level of the chain can paralyze the entire factory. Every link is important for the whole.

I had already worked in a factory before, but in much smaller size and less automated. This internship in a multinational such as Heineken has allowed me to understand the industrial world more easily.

Despite the fact that I was operator, (which does not require special skills), I have always looked at my surroundings with curiosity and desire. I saw things as a future engineer. So I was delighted the machines, their speed of execution unbelievable, but also by the multitude of sensors that can detect the slightest defect.

c- Difficulties

i) Noise   : The first thing that strikes in the factory is the noise. The bottles hit themselves and the noise goes from 84Db to 91Db so everywhere, earplugs are required.

Only experience of working in a noisy environment may give such felt about this scourge. It is important in my opinion that each engineer know it in order to limit it from the source; and in this way facilitate the work of operators.

A sound recording is available at the address below. That's what you hear when a person speaks to you normally. http://tptz.free.fr/Heineken/BRUIT-HK

ii) Broken glass   : Inside the factory, the glass is everywhere and sometimes moves at high speed. The risk of breakage is permanent and operators are often exposed to pieces of glass. Sometimes (and it happened to me) a bottle explodes near you. I have sometimes taken projections of glass in the eye which is very impressive but glasses stop them. I have learnt quickly to turn the head when there was a danger. But I had to be careful, wear gloves as often as possible and never removed my glasses.

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ConclusionEven if everything was not easy, because operator work is very repetitive, I think it is essential to get more professional experience. It’s really in internship that we discover the industrial world that we don’t know enough in school.

A have realize how much I was lucky to do this studies. So I can confirm that I have chosen the right way for my future.

It is true that I wasn’t happy by the internship of 6 months of the second year, but my way of thinking has changed. Indeed with this internship, I discovered how much we could learn in a company. But it was only a worker internship. So I look forward to my engineer internship of 6 months, because in my opinion I will learn a lot. Moreover, I will normally do in aeronautic sector, which is the sector I'm particularly fond.

Finally, I will just say thank you to Supméca to give us the opportunity to increase our professional experience that will enable us to get to a job easily.

Remember to go onhttp://tptz.free.fr/Heineken/

To find video and audio files that I created

To consume without moderation