This document summarizes the results of a project to transform a manufacturing process and meet several key criteria: 1) Meet savings targets through lower material costs and a faster time to market through Asia's one month roll out capability. 2) Achieve zero safety and quality incidents, and meet public relations glide path targets. 3) Leverage excellence programs to ensure readiness for startup through detailed planning, learning from other sites, and standardized validation protocols. 4) The project results included record high production rates for the lines during initial runs, zero safety incidents, one minor quality incident, coming in under budget and reducing construction time.

1. TDC Savings:
Materialcost (0.06$/SU)
SpeedtoMarket:
Asia “One Month”Roll OutCapability
BusinessNeed ProjectWorkplan
•Zero safety & Quality incident
•Meet savings success criteria
•Meet PR Glide path
GSUM+ & IWSExcellence
Transforming "India 3Bn+ Dream" Into Reality
Safety and Construction excellence
Standardization
Seamless collaboration in MFT
Rightthefirsttime-
OntimeStartup afterShutdown
Leveragingglobalsitelearning
to captureall LFE
RESULTS
Readiness:Rightto succeed
• Detailed2monthsPRLoss fortheZone-4 analyzed,actionplanspriorstartup
• Discussedstartupissues withtheplatformleaders,otherstartupleaders
• Learning&C/Lpackagesfromregionalleadlinesites
Installation
• IdentifiedBCP
• Clearlyidentifiedtheconstructionandstartupteam
Capabilitybuildingleveraginglead&site-sistersiteconcept
• TT&T-DevelopedpackageforLineleaders&ProcessEngineers
• ClassroomandOJTto trainandqualifystartupteam
Smoothexecution ofevery phase(installation,CQV) withminimumrework
• 4M readiness
• IntegratedReviewthroughSupplyChainReadinessDDS
• Seamlesscollaborationwith otherplantsCEEMEA,Cairo
• OneTeam–LaunchTeam,Planning,LineOperations,PM,Safety, QualityPurchase,MDSO
Design andconstruction–Well
communicatedtothevendor
Standardizedvalidation
protocolsacrosslines
 MRCLscore>%
 AEspendwith intarget
 AMstep4compliantequipments/PMstep2readiness
done.
RigorinfollowingallGSUM+tools
 100%GSUMcompliance–TT&T, MRCLetc.
 Designinputs– EnsuredFormingshouldertunnel
dimensionchange key learningfromCairoleadline
 Leveraging dailyDDS–workprioritizationandaction
closure
Achieved92.6%PRin the8hourruninT-3in
LCC-4 on5thmarchis therecordforthis projectglobally.
Achieved93.4%PRin the8hourruninT-5in
LCC-3 on13thmarchisthe recordforthisprojectglobally
Safety Incidents
Zero
Quality Incidents
Zero U/H due to
pouch open
PR (8 Hour Run)
T-3= 92.6% ,
T-5= 93.4%
T-5 Becca=89%
Cost
Old PF Inventory
Run Out < 100%
G2T- Const. + Comm.
13.5 hrs v/s 16 hrs
Reduced Pouch Film Initiative