Bridging Classroom Insights with Internship Experience: Final Takeaways from my PepsiCo Internship

As my production internship with PepsiCo comes to a close, I am incredibly grateful for this opportunity. Over the past ten weeks, I have experienced significant personal and professional growth. My role as a Production Intern involved a range of responsibilities crucial to the smooth operation of the manufacturing process. Specifically, I was tasked with two main projects: first, reducing our average flavor changeover times from 55 minutes to 30 minutes, and second, creating a sustainability plan to optimize recycling credits by differentiating between full and empty cans and bottles.

These projects were essential for several reasons. Reducing flavor changeover times was critical for enhancing production efficiency and maximizing output. Faster changeovers meant less downtime between product runs, which directly improved our production capacity and helped meet consumer demand more effectively. This improvement not only lowered operational costs but also strengthened PepsiCo’s competitive edge in a fast-paced market.

On the sustainability front, developing a plan to accurately sort full versus empty containers addressed both environmental and operational concerns. By obtaining recycling credits, PepsiCo could reduce waste and improve its environmental footprint. This project supported the company’s commitment to sustainability, demonstrating a proactive approach to responsible manufacturing practices while potentially lowering disposal costs and enhancing our brand’s reputation as an environmentally conscious leader.

One of the most valuable aspects of my internship has been the chance to tackle real-world challenges faced by our plant daily. Unlike typical school projects, which often involve simulations or prescribed solutions, my work with Pepsi has taught me that finding a solution or implementing a project exactly as envisioned is not always feasible. I’ve been fortunate to learn from experienced managers and employees who guided me through the complexities of not having complete control over every aspect of a project—an adjustment from my usual lecture-based experiences. Additionally, I extended my networking efforts nationwide, seeking advice from various locations. For instance, during my flavor changeover project, I faced setbacks that initially left me discouraged. However, I revisited my approach and engaged with Pepsi production supervisors, managers, and engineers across the country. While industry best practices offer valuable insights, successful project implementation often requires significant cultural and attitude shifts within the plant. By incorporating the advice of my colleagues and actively engaging with the frontline team, I worked to ensure a smoother and more effective implementation of my projects.

In my first project, I focused on Knoxville's Bottle Line 2, one of only two lines in the division producing 16.9oz 12-packs. Despite operating at full capacity, I was tasked with optimizing the flavor changeover process to streamline operations and reduce downtime. Initially, this line averaged a 52.9-minute flavor changeover. The goal of my project was to reduce this time to 30 minutes or less. By effectively achieving this, Bottle Line 2’s availability would increase by 108 production hours in the second half of the year, leading to a significant boost in production capacity. This improvement is projected to add an additional 95,000 cases to the market, enhancing product availability and meeting consumer demand more effectively. Overall, this optimization not only maximizes the line's efficiency but also contributes to increased market presence and revenue potential. To enhance the flavor changeover process, I closely observed current procedures to identify areas for improvement. Engaging with frontline operators and gathering their feedback was crucial for making practical enhancements and ensuring that any changes were effective and well-supported by those directly involved.

My second project involved a recycling initiative at the Knoxville site. I established a streamlined process for managing and processing recyclables, aiming to maximize both environmental impact and financial benefits. This system began with collecting all recyclables at the Knoxville site, where I focused on accurately sorting empty versus full containers. Although the recycling process remained consistent during my internship—routing empty cans to the local recycling plant and consolidating empty bottles at a baler for Waste Management—I noticed that many frontline operators were discarding cans and bottles inappropriately. Despite full containers being sent to another Pepsi location for reuse, some operators were incorrectly disposing of these in bins meant for empty items. To address this, I evaluated key areas and sought feedback on potential improvements. I conducted plant walk-throughs to identify where additional totes and bins were needed and implemented a systematic 5S approach, including clear labeling and designated areas. This method not only helps in obtaining valuable recycling credits but also enhances financial returns by ensuring that recyclables are processed correctly and efficiently.

Although ten weeks initially seemed sufficient to complete both projects, I’ve learned that several months are needed to sustain initiatives, especially those requiring significant cultural shifts. My flavor changeover project showed some success but will require ongoing operator accountability and management oversight to ensure adherence to the new processes. To address this, I developed sign-off sheets to track compliance and maintain the new procedures. Additionally, while some operators have adopted the revised sorting and recycling methods, others have reverted to previous habits. Recognizing that change can be challenging, I created laminated signs and clearly designated areas to reinforce these practices. This will help ensure that even after my internship ends and I return to school, these improvements continue to be supported and eventually embraced by all team members.

Overall, applying theoretical knowledge to practical challenges during this internship has led to immense personal and professional growth. Personally, I learned the importance of effective change management and communication. Building strong rapport with frontline employees was crucial in overcoming resistance to change and ensuring a smoother transition. Professionally, I discovered the benefits of bottom-up planning—listening to the needs of those on the ground and adapting processes to better support them proved essential for success. I also embraced the principle of progress over perfection, focusing on what worked rather than dwelling on shortcomings. Additionally, I learned to make quick, decisive actions when projects didn’t go as planned, understanding that not every initiative will yield perfect results. These lessons have significantly enhanced my ability to manage change, communicate effectively, and lead more resiliently.