GSC meeting PM - Final

GSC MENEAT
Tanzania Factory
David Nderimo
Regional GSC meeting, March 12-16, 2012
Engineering –
Project Management

© Copyright JTI 2012
Engineering – Project management
Engineering - Project Management
Organization chart
Martin MARIKI
Project Engineer
Shabani WAZIRI
Draftman
David NDERIMO
Project Manager
Martin PORTZ
Project Engineer
STA

Recently completed projects
3Engineering - Project Management

Factory water network
• Replacement of worn out 50 years old water
network
• Connecting of 3rd
borehole to water network
• Installation of water softener
• Implementation of water flow meter for
monitoring
4
Completed in February 2012

Partial upgrade of new site warehouse
• Upgrade of part of semi finished warehouse
(Mezzanine) with a total area of 1,800m² out
of 10,000m²
• Operation with automatic exhaust heat fans
• Using natural light (Transparent sheets)
• Hygienic condition surface floor
• The warehouse is now used for tobacco
storage
5
Completed in January 2012

Extension of fire detection system to
• Parts of newly installed Primary (Flash dryer)
• TP filter room
• Upgraded warehouse
• Fire pump area
Fire detection system extension
Completed in January 2012

Projects in progress

2nd
gas engine
• Description
• Installation of additional 1MW electricity generating capacity to meet increased energy demand due to
new Primary and additional Make/Pack machines
• Goal
• Ensure stable and sufficient power supply to support volume growth
• Status
• Preparation works in progress
• Engine delivered; Synchronization panel in transit
• Key equipment installation start: 04/12
• Commissioning: 05/12
Marketing budget

Make/Pack and Cutfiller Storage HVAC
• Description
• Extension of existing HVAC system in Make/Pack due to increased area and heat load
• Replacement of existing Cutfiller AHU due to increased storage area
• Goal
• Improve machine performance
• Improve product quality
• Be in line with policies and procedures
• Status
• Preparation works in progress
• Key equipment partially delivered; rest expected to be cleared by mid of March 2012
• Installation start: 04/12
ASP 2011-2012

© Copyright JTI 2012 10
New cutfiller AHU New Make/Pack AHU
Exisiting Make/Pack AHU Engineering - Project Management

Boiler Replacement and Co-generation
• Description
• Replacement of one old boiler and making use of waste heat of gas engine #1
• Waste heat recovery of engine #2 not in scope
• Goal
• Reliable and cost efficient steam supply
• Possible funding by Belgium government (subsidy directly paid to supplier) up to 50% of the equipment
with a maximum of 247.500 Euro
• Status:
• Application for subsidy: 01/12
• Feedback for subsidy: expected in 03/12
• PO: 04/12 (after feedback for subsidy)
• Installation: 10/12
ASP 2011-2012

New boiler house
Existing boiler house

KDF line
• Description
• The current situation with JTI Tanzania is having two Filter makers (Rebuild KDF 2ER and KDF 2
overhauled by HAUNI)
• While the volume growth in make/pack has made an increase of the filter demand, it is necessary to
increase the capacity in the filter production to avoid the risk of having insufficient filter supply to the
makers and lowering the loading level to below 95%.
• Goal
• Avoid overtime
• Meet volume demand
• Status:
• Future Make/Pack layout to be finalized and agreed with production
• Machine in transit; expected to be cleared by mid of March 2012
ASP 2012

Printers for export product
• Description
• Democratic Republic of Congo (DRC) requires printing of three lines on each pack
(Date of Manufacturing, Date of Expiration and Lot number of the product)
• Current domino ink jet printers do not have the capability of meeting this requirements
• Therefore two X500 packing lines need to be equipped with new printer
• Goal
• Meet regulatory requirements for DRC market
• Status:
• Original delivery time 04/12
• New delivery time 07/12 (Delay of 2 month)
ASP 2011-2012

4th GD 121/X 500 line
• Description
• Installation of additional soft pack line (GD 121-AF 12, GD B 21, GD X 500, GD C800 and Taurus filter
mass flow) to provide sufficient capacity to cope with the increasing volume demand - driven by both the
Tanzania domestic and East African markets
• Goal
• Reduce loading level of soft pack lines
• Increase flexibility in production
• Meet market volume demand as per ASP
• Status:
• Future Make/Pack layout to be finalized and agreed with production
• FAT / pre-inspection: 07/12
ASP 2011-2012

Planned projects

GD X2 electronics update
• Description
• Replacement of obsolete Micro I plc control
• Goal
• Ensure availability of machine
• Status:
• Quotation from GD on hand
• BAP prepared and on internal circulation  expected to be submitted by end of March 2012
• BAP approval: 04/12
• PO: 05/12
ASP 2012-2013

Rejects and Shorts buffering
• Description
• Installation of rack system in production area to generate space for Rejects and Shorts to avoid outside
buffering
• Goal
• Reduce material handling
• Optimize work flow
• Status:
• Layout change of QC lab extension
TP Upgrade

Shorts tipper
Shorts buffering
QC extension

Outlook / focus areas

Primary
• Utilities
• Steam pipe
• Waste water drainage
• Segregating Primary from outside
• Emergency exits / doors
• Roller shutters
• Roof insulation
• Windows
• Ventilation system
Pending issues

Reduction of idle times in Primary
• Description
• Lamina and CRES line are in direct connection via two old silos, but of non-matching capacities
• High idle times on Lamina line waiting for CRES
• Goal
• Reduce idle times ( reduction of working hours and energy need)
• Optimize operation
• Status:
• Alternative 1: CRES buffering in C-48 and adding back via tipper
• Alternative 2: Replace existing two old silos by two new double layer silos (in total 4 silos)
• Next steps
• Conduct feasibility study to investigate different alternatives in detail
• Share results: 04/12
Study

CRES box off CRES silos
Addback tipper

New concept for batch preparation
• Description
• Due to limited space inside Primary tobacco batches are prepared and stored outside
• This causes a lot of fork lift traffic as well as limited overview
• Goal
• Reduce handling
• Optimize operation
• Increase safety on site
• Status:
• Alternative 1: Convert old boiler house
• Alternative 2: Convert former heavy fuel oil storage
• Next steps
• Conduct feasibility study to investigate different alternatives in detail
Study

Former heavy fuel
oil storage
Boiler house

Finalizing semi-finished warehouse on new site
• Description
• Due to limited storage capacity Tanzania factory is renting outside storage
• Required space: 20,350 m2
• Available space: 11,819 m2
• Deficit: 8,531 m2
• Goal
• Provide sufficient storage capacity for NTM, FG and tobacco on site
• Status:
• Available space to be completed is 8,400 m2
• Estimated cost of work to complete is $ 2,132,750 (at the cost 250$/m²)
• Next steps
• Conduct feasibility study to investigate in detail
Study

The future of Project
Management section

The future of Project Management section
The department will merge as per ‘JTIs best practice’
Draftsman
Maintenance ENGINEER
Engineering MANAGER
Utility ENGINEER Project ENGINEER

David Nderimo
The department will merge as per ‘JTIs best practice’

GSC meeting PM - Final

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