SlideShare a Scribd company logo
1
Accelerate volume growth and
gain NARTD share across all
categories while reducing PoH +
Opex and step-changing EBIT
margin, capabilities and talent
pool.
Our Job Ticket
Our Supply Chain Model
3
Demand
Driven
Quality
Customer
ServiceCost
Supply Chain Goal
• Deliver Quality Performance : BPQI >=95% , PCQI >=92%, MQI >= 85%
• Drive Opex reduction by 6% basis excluding Depreciation Vs PY
• Improve System Line Efficiency by 6% basis
• Drive Production Compliance above 90%
4
EAST CENTRAL SUPPLY CHAIN
STRATEGIC FOCUS
Strengthen
Leadership
Capability
Development
Functional
Maintenance
Structure and
Routines
Pre-emptive
community mgt
Process
Management
System
Embed Quality
and Safety
Culture on the
shopfloor
6
2013 Performance Overview
RGB CAPACITY UTILISATION – EAST CENTRAL
Key Assumption
1,083 1,083 1,750 1,250 1,500
833 0 1,500 0 0
100% 100% 80% 100% 100%
0% 0% 20% 0% 0%
45% 48% 40% 50% 52%
52% 52% 50% 52% 55%
53% 55% 52% 55% 58%
OWERRI PORT HARCOURT EAST
Utilisation Utilisation
Total Owerri1 Owerri2 Owerri4 Total Total PHC1 PHC2 Total
2014 19,071,734 5,398,719 5,758,633 8,102,171 19,259,523 99% 10,849,092 6,923,565 8,640,609 15,564,173 70% 29,920,827 34,823,697 86%
1.04
2015 19,834,604 6,238,519 6,238,519 10,127,714 22,604,753 88% 11,283,056 7,200,507 9,139,105 16,339,613 69% 31,117,660 38,944,365 80%
1.04
2016 20,627,988 6,358,491 6,598,434 10,532,823 23,489,748 88% 11,734,378 7,615,921 9,637,602 17,253,523 68% 32,362,366 40,743,271 79%
Sales Est Capacity Utilisation
Line cap. (cph)
Package Contrib. (%)
Yearly SLE
Sales Estimates Capacity
Line cap. (cph)
Package Contrib. (%)
Yearly SLE
CapacitySales Estimates
Key Assumption
1,750 1,750 1,750 1,750
1,250 1,250 0 1,250
60% 100% 100% 40%
40% 0% 0% 60%
45% 45% 50% 50%
50% 50% 52% 50%
53% 53% 53% 53%
Benin Enugu Central
Utilisation
AsabaSales Estimate Ben1 Ben2 Total ENU 1 ENU 2 Total
2014 17,787,512 8,794,197 8,723,691 17,517,889 102% 13,314,203 9,692,990 9,810,500 19,503,491 68% 31,101,716 37,021,379 84%
1.04
2015 18,499,013 9,771,330 9,692,990 19,464,321 95% 13,846,771 10,080,710 9,810,500 19,891,210 70% 32,345,784 39,355,531 82%
1.04
2016 19,238,973 10,357,610 10,274,570 20,632,180 93% 14,400,642 10,274,570 10,399,130 20,673,700 70% 33,639,616 41,305,880 81%
UtilisationSales Estimates Utilisation prod CapSales Est
Capacity Capacity
Line cap. (cph) Line cap. (cph)
Package Contrib. (%) Package Contrib. (%)
Yearly SLE Yearly SLE
Manufacturing
KBIs 2012 FY 2013 FY 2013 BP Vs PY Vs BP
Manufacturing Cost Per Case 176.0 173.8 143.2
SLE 51.9% 41.5% 58.0%
Concentrate Yield 99.1% 98.9% 99.4%
Sugar Yield 99.0% 98.8% 99.2%
Crown Wastage 1.6% 1.7% 0.7%
Bottle Breakages 0.62% 0.53% 0.57%
CO2 Yield 55.5% 57.8% 60.0%
LOB/Kwhr 13.0 13.2 15.1
PHC/LOF Boiler 13.4 14.8 12.4
Caustic Usage 1.6 1.6 1.5
Production Compliance 60% 75% 80%
Quality and Sustainability
KBIs 2012 FY 2013 FY 2013 BP Vs PY Vs BP
SAFETY: LTA 12.0 8.0 0.0
SAFETY: FAI 127.0 129.0 64.0
SAFETY: FATALITY 0.0 1.0 0.0
BPQI 92.5% 89% 95%
PCQI 85.6% 83% 91%
Date Code 95.8% 93.0% 97.0%
Net Content 93.4% 94.0% 96.8%
PDQI 78.0% 83.5% 83.0%
Water Usage Ratio 2.73 2.13 2.59
Energy Usage Ratio 0.60 0.56 0.53
Solid Waste Ratio 18.47 23.52 17.45
2013 – Key Learnings
SYSTEM
LINE
EFFICIENCY
QUALITY
AND
SUSTAIN-
ABILITY
COST
LEADERSHIP

Inadequate operating and maintenance
skill
 Problem Solving lengthy due to skill
Team Management weak
OPL driven mainly by Forlift availability
and reliability
Glass returnability could be better
managed
Spares management still challenging
Better line overhaul execution but
preparation needs improvement
Better Line scheduling can help utilisation
PPE compliance still a challenge
Incoming material inspection inadequate
Shopfloor involvement in quality
inspection
Ownership for on-line quality control
equipment operation and maintenance
Use Process monitoring and control to
drive quality improvement
GMP/GHK standard improvement
Audit CAP review inadequate
Toolbox Talk Execution Inadequate
Pre approval process key in controlling
casual usage and overtime
Focus on energy projects
Regular reconciliation on
area/equipment basis helps in Yields and
breakages control
Better and Timely equipment
maintenance helps control business loss
Plant level cost review on weekly basis
Inadequate Quality control lead to high
business loss due to manufacturing defects
Ineffective incoming glass inspection
both from Trade and new glass led to hogh
cost of glass write-off
12
1. KHS line rebuild
2. Execute RGB Lines Overhaul Plan
3. End of Line automation in
Benin(Palletiser)
4. Owerri Lines 1 & 2 Upgrade
5. Leverage SAP PM and EATB Kaizen
6. Leverage GPIT and TNT Support
7. Ultra Glass Injection Impact
8. Volume Allocation in Central(benin to
Enugu) during Peak Season
9. Minimum Run Size Adherence and
Speed Loss Eliminination
1. Leverage New PHC PET Line
2. Benin PET line Overhaul
3. Juice Line 4 TPMS
4. Owerri PET EvA Line overhaul
5. Leverage on new end of line
equipments on Benin Line 6
6. Leverage SAP PM and EATB
Kaizen
7. Leverage GPIT and TNT support
for Benin and Owerri
8. Transition to 48h CIP on Eva line
9. Reinforce Incoming inspection of
packaging materials e.g pallets,
films etc
1. Effective glass management
2. Enforce Glass Staging across all
Plants
3. Forklift Management(TAT and
Maintenance)
4. Enforce EATB PM across all
Plants – Weekly and Monthly
for STLs and LM
5. Line schedule optimisation
6. Mixer Operator Assessment and
Skill Upgrade
1. SMED Implementation across
all Plants
2. Restoration of CIP system into
Auto Mode
3. Synchronisation of
CIP/Changeover Timing
RGB SLE
Up By 3%
OWP SLE
Up By 6%
OPL Down
By 50%
CIP/
Changeover
Time
reduction
PRODUCTIVITY
1313
1. Leverage Juice line TPMS
2. Benin PET Filler Overhaul
Impact
3. Benin Line 1 and 2 filler
overhaul
4. Mixer Overhaul and
operator training
1. Tracking and reconciliation on
shift basis
2. Leverage RGB line overhauls
3. Ultra Glass Introduction Impact
4. Proper Glass sorting process at
Plant and Depot
5. Enforce Proper CIP/Changeover
practices as it relates to Washer
1. Weekly Pre approval process
2. Weekly cost review and CAP
3. Leverage SLE improvement to
minimise run days
4. Energy management /Load
Shedding during Non Production
Period
5. Implement Top 10 menergy sevres
to reduce consumption
6. UPS Capacity increase and
introduction in relevant plants
1. Effective sorting in trade
2. Implement proper glass handling
practices in Plant and Depot
Reduce
Manufacturin
g Defects
<PY
Reduce
Bottle
breakages
<0.5%
Overtime ,
Casual and
Energy Cost
Management
in line with
BP
Scuff Glass
Managemen
t
Drive Manufacturing Cost Improvement Through Business Loss
and Overhead Reduction
COST LEADERSHIP
1414
1. Coding Machine Upgrade and
Overhaul
2. Effective Power Protection in
Place
3. Implement OEM Standards for
operation
4. Operator Involvement in On-line
Quality control(15minutes check
by filler operator)
5. Installation of Laser coders on all
PET lines
6. Fully functional standby coders on
all RGB lines
1. Implement revised Vent tube
management
2. Filling valves and lift cylinders
validation and Maintenance
3. Operator Involvement in On-line
Quality control
4. Check mat Functionality Audit and
Access Control
5. Robus incoming inspection and
adherence to 1000cases run for new
glass
1. Enugu Lines fully ASEBI
2. Miho Asebi Maintenance
Schedule compliance
3. Mixer Operator Training
4. Implement Effective DO
Management: Daily tracking,
Review and implement CAP for
out of limits
5. Regular Crimp checks and
control by Filler operator
1. Regular System audit action plan
tracking and review
2. Biannual Compliance Self
assessment
3. Yearly Kore Standards
Training/Refresher(Virtual
Factory)
4. Process monitoring and control
across all plants
5. B2B rollout in EC
Date Code
Net Content Carbonation
Quality
Systems
Compliance
Drive Quality Through Shopfloor Engagement and
Accountability
QUALITY
1515
1. Daily random PPE Compliance by
PMs
2. Daily Tool Box Talk in SBT and
weekly in PM meetings
3. Implement weekly Hazard
spotting and correction
4. Enforce Hot work permit
5. Ensure all Machine guarding fully
functional
6. Enforce Energy isolation(LOTO)
in plants
1. Fully functional Fire
protection: Extinguishers
and Hydrant system
2. Enforce Drill Schedule
3. Fire Alarm Systems Fully
functional
Implement
Preventive
Systems
Implement
Protection
Systems
Drive Safety and Environmental ComplianceThrough Zero
Tolerance to Non Compliance and standards implementation
Safety
Regulatory
Compliance
1. Regular System audit action
plan tracking and review
2. Biannual Compliance Self
assessment and Corrective
action Planning
SUSTAINABILITY – SAFETY
AND ENVIRONMENT
1. Restore all Plants ETP to full
functionality
2. Ensure all water meters are fully
functional and calibrated
3. Implement agreed WUR and
SWR projects in all plants
4. Drive implementation of key
energy reduction initiates eg UPS
Enugu, Gas Generator sets for
owerri
Environmental
Systems
Compliance
Capability Development
Top Key issues
Line Management
Quality Knowledge especially on the shop floor
Preventative Maintenance
 Deep Diving Skill
Key Initiatives
Rollout of EAtB across East and Central Plants
Technical Training for Key Equipment operator - Mixer
Production, Quality Assurance, Plant Engineer Development Programme
Simplified BQAT to the shop floor
Levarage New PHC PET CSD Line to Upscale technical skill
All PMs Enrolled in Accenture Supply Chain Academy
Leverage TTC Graduate Trainee
 Line Manager Development Curriculum
B2B Rollout across East Central
Sales Volume: 87.05MUCS
DIFOTAI: 90%
SLE: 54.4%
Production Compliance: 85%
Manufacturing Cost, CPC: =N=152.51/Case
Concentrate Yield: 99.32%
Sugar Yield: 99.12%
Business Loss: 50% below PY
MQI: 84%
BPQI: 94.5%
PCQI: 92%
Date Code: 97%
FAI: 50% below PY
LTA: 0
Fatality: 0
WUR 2.50
EUR 0.48
Customer
Preference
Cost
Leadership
Consumer
Relevance
Community
Trust
People & Capability
Capability Development: 85% IDP Compliance
Quality and Safety Audits: 100% Compliance
EATB Audits : All 4 Plants Certified
EC 2014 PICTURE OF SUCCESS
EC  plan 2014 Final Revision

More Related Content

What's hot

Case Study: Telecom Equipment Manufacturer Enhances QMS to Streamline Returns...
Case Study: Telecom Equipment Manufacturer Enhances QMS to Streamline Returns...Case Study: Telecom Equipment Manufacturer Enhances QMS to Streamline Returns...
Case Study: Telecom Equipment Manufacturer Enhances QMS to Streamline Returns...
Paul Adamson
 
Ray Hopkinson Resume Feb 15_2015
Ray Hopkinson Resume Feb 15_2015Ray Hopkinson Resume Feb 15_2015
Ray Hopkinson Resume Feb 15_2015
Ray Hopkinson
 
MCS
MCS MCS
Validation and Verification of HACCP Plans - Webinar Presentation
Validation and Verification of HACCP Plans - Webinar PresentationValidation and Verification of HACCP Plans - Webinar Presentation
Validation and Verification of HACCP Plans - Webinar Presentation
SAIGlobalAssurance
 
Magna supplier quality_requirements_manual_rev2
Magna supplier quality_requirements_manual_rev2Magna supplier quality_requirements_manual_rev2
Magna supplier quality_requirements_manual_rev2
Dr Lendy Spires
 
zeeshan
zeeshanzeeshan
zeeshan
Zeshan Ali
 
1MP from Comecer
1MP from Comecer1MP from Comecer
1MP from Comecer
Comecer
 
SQF Audits - Top 10 Non-conformances of 2014
SQF Audits - Top 10 Non-conformances of 2014SQF Audits - Top 10 Non-conformances of 2014
SQF Audits - Top 10 Non-conformances of 2014
Tara Lacey Guthrie
 
Howard, Steve QA Sanitation and Quality
Howard, Steve QA Sanitation and QualityHoward, Steve QA Sanitation and Quality
Howard, Steve QA Sanitation and Quality
Steve Howard
 
HACCP Principles for Operators in Food Services and Retail Establishment.
HACCP Principles for Operators in Food Services and Retail Establishment. HACCP Principles for Operators in Food Services and Retail Establishment.
HACCP Principles for Operators in Food Services and Retail Establishment.
Eng. A.karam Al Malkawi
 
Inside the Mind of a Food Safety Auditor
Inside the Mind of a Food Safety AuditorInside the Mind of a Food Safety Auditor
Inside the Mind of a Food Safety Auditor
TraceGains
 
Intro to cGMPs: The Building Blocks for GFSI Compliance
Intro to cGMPs: The Building Blocks for GFSI ComplianceIntro to cGMPs: The Building Blocks for GFSI Compliance
Intro to cGMPs: The Building Blocks for GFSI Compliance
TraceGains
 
CV CS
CV CSCV CS
Plant Management and Business Development
Plant Management and Business DevelopmentPlant Management and Business Development
Plant Management and Business Development
Major Deng
 
ANNEXTURE -2 WORK EXP OF N M KULKARNI
ANNEXTURE -2 WORK EXP OF N M KULKARNIANNEXTURE -2 WORK EXP OF N M KULKARNI
ANNEXTURE -2 WORK EXP OF N M KULKARNI
Narayan Kulkarni
 
Gwendolyn Beagle resume
Gwendolyn Beagle resumeGwendolyn Beagle resume
Gwendolyn Beagle resume
Gwen Beagle
 
Sherrie Webb - Common Industry Audit, Producer Update
Sherrie Webb - Common Industry Audit, Producer UpdateSherrie Webb - Common Industry Audit, Producer Update
Sherrie Webb - Common Industry Audit, Producer Update
John Blue
 
Preparing for your Food Safety Audit
Preparing for your Food Safety AuditPreparing for your Food Safety Audit
Preparing for your Food Safety Audit
PECB
 
Proj302_Poster_CEM_AYDEDE_1October2013
Proj302_Poster_CEM_AYDEDE_1October2013Proj302_Poster_CEM_AYDEDE_1October2013
Proj302_Poster_CEM_AYDEDE_1October2013
Cem Aydede
 
WHO GMP Requirements
WHO GMP  RequirementsWHO GMP  Requirements
WHO GMP Requirements
Deekshitha HS
 

What's hot (20)

Case Study: Telecom Equipment Manufacturer Enhances QMS to Streamline Returns...
Case Study: Telecom Equipment Manufacturer Enhances QMS to Streamline Returns...Case Study: Telecom Equipment Manufacturer Enhances QMS to Streamline Returns...
Case Study: Telecom Equipment Manufacturer Enhances QMS to Streamline Returns...
 
Ray Hopkinson Resume Feb 15_2015
Ray Hopkinson Resume Feb 15_2015Ray Hopkinson Resume Feb 15_2015
Ray Hopkinson Resume Feb 15_2015
 
MCS
MCS MCS
MCS
 
Validation and Verification of HACCP Plans - Webinar Presentation
Validation and Verification of HACCP Plans - Webinar PresentationValidation and Verification of HACCP Plans - Webinar Presentation
Validation and Verification of HACCP Plans - Webinar Presentation
 
Magna supplier quality_requirements_manual_rev2
Magna supplier quality_requirements_manual_rev2Magna supplier quality_requirements_manual_rev2
Magna supplier quality_requirements_manual_rev2
 
zeeshan
zeeshanzeeshan
zeeshan
 
1MP from Comecer
1MP from Comecer1MP from Comecer
1MP from Comecer
 
SQF Audits - Top 10 Non-conformances of 2014
SQF Audits - Top 10 Non-conformances of 2014SQF Audits - Top 10 Non-conformances of 2014
SQF Audits - Top 10 Non-conformances of 2014
 
Howard, Steve QA Sanitation and Quality
Howard, Steve QA Sanitation and QualityHoward, Steve QA Sanitation and Quality
Howard, Steve QA Sanitation and Quality
 
HACCP Principles for Operators in Food Services and Retail Establishment.
HACCP Principles for Operators in Food Services and Retail Establishment. HACCP Principles for Operators in Food Services and Retail Establishment.
HACCP Principles for Operators in Food Services and Retail Establishment.
 
Inside the Mind of a Food Safety Auditor
Inside the Mind of a Food Safety AuditorInside the Mind of a Food Safety Auditor
Inside the Mind of a Food Safety Auditor
 
Intro to cGMPs: The Building Blocks for GFSI Compliance
Intro to cGMPs: The Building Blocks for GFSI ComplianceIntro to cGMPs: The Building Blocks for GFSI Compliance
Intro to cGMPs: The Building Blocks for GFSI Compliance
 
CV CS
CV CSCV CS
CV CS
 
Plant Management and Business Development
Plant Management and Business DevelopmentPlant Management and Business Development
Plant Management and Business Development
 
ANNEXTURE -2 WORK EXP OF N M KULKARNI
ANNEXTURE -2 WORK EXP OF N M KULKARNIANNEXTURE -2 WORK EXP OF N M KULKARNI
ANNEXTURE -2 WORK EXP OF N M KULKARNI
 
Gwendolyn Beagle resume
Gwendolyn Beagle resumeGwendolyn Beagle resume
Gwendolyn Beagle resume
 
Sherrie Webb - Common Industry Audit, Producer Update
Sherrie Webb - Common Industry Audit, Producer UpdateSherrie Webb - Common Industry Audit, Producer Update
Sherrie Webb - Common Industry Audit, Producer Update
 
Preparing for your Food Safety Audit
Preparing for your Food Safety AuditPreparing for your Food Safety Audit
Preparing for your Food Safety Audit
 
Proj302_Poster_CEM_AYDEDE_1October2013
Proj302_Poster_CEM_AYDEDE_1October2013Proj302_Poster_CEM_AYDEDE_1October2013
Proj302_Poster_CEM_AYDEDE_1October2013
 
WHO GMP Requirements
WHO GMP  RequirementsWHO GMP  Requirements
WHO GMP Requirements
 

Similar to EC plan 2014 Final Revision

MVR BEFORE RAMP
MVR BEFORE RAMPMVR BEFORE RAMP
MVR BEFORE RAMP
RAMANA M V
 
Productivity Benchmarking in Spinning Mills
Productivity Benchmarking in Spinning MillsProductivity Benchmarking in Spinning Mills
Productivity Benchmarking in Spinning Mills
Kanthimathinathan Aramvalarthanathan
 
ENVOGUE - Energy Trending!
ENVOGUE - Energy Trending!ENVOGUE - Energy Trending!
ENVOGUE - Energy Trending!
Umesh Bhutoria
 
Asik Ali Battery Production and Maintenance
Asik Ali Battery Production and MaintenanceAsik Ali Battery Production and Maintenance
Asik Ali Battery Production and Maintenance
Asik Ali
 
dipankar bandyopadhyay_6787_GR_A
dipankar bandyopadhyay_6787_GR_Adipankar bandyopadhyay_6787_GR_A
dipankar bandyopadhyay_6787_GR_A
Dipankar Bandyopadhyay
 
Apply model predictive control to reduce batch cycle time and increase consis...
Apply model predictive control to reduce batch cycle time and increase consis...Apply model predictive control to reduce batch cycle time and increase consis...
Apply model predictive control to reduce batch cycle time and increase consis...
ARC Advisory Group
 
Job description factory services engineer
Job description   factory services engineerJob description   factory services engineer
Job description factory services engineer
Babatunde Sofoluwe
 
Peter cv
Peter cvPeter cv
Peter cv
peter nganga
 
Asia NOC Bridges Business-wide Performance Objectives and KPIs through an Adv...
Asia NOC Bridges Business-wide Performance Objectives and KPIs through an Adv...Asia NOC Bridges Business-wide Performance Objectives and KPIs through an Adv...
Asia NOC Bridges Business-wide Performance Objectives and KPIs through an Adv...
Yokogawa1
 
EECO2 GMP critical HVAC energy cost reduction
EECO2 GMP critical HVAC energy cost reductionEECO2 GMP critical HVAC energy cost reduction
EECO2 GMP critical HVAC energy cost reduction
Keith Beattie
 
An introduction to EECO2-Energy Efficiency Consultancy Limited
An introduction to EECO2-Energy Efficiency Consultancy LimitedAn introduction to EECO2-Energy Efficiency Consultancy Limited
An introduction to EECO2-Energy Efficiency Consultancy Limited
EECO2
 
Smart Pharmaceutical Consulting - Lean Manufacturing of Pharmaceuticals
Smart Pharmaceutical Consulting - Lean Manufacturing of PharmaceuticalsSmart Pharmaceutical Consulting - Lean Manufacturing of Pharmaceuticals
Smart Pharmaceutical Consulting - Lean Manufacturing of Pharmaceuticals
Christopher Macklin
 
Tolling group leader Positions
Tolling group leader PositionsTolling group leader Positions
Tolling group leader Positions
Weidong Ping
 
Resume Suresh Patel
Resume Suresh PatelResume Suresh Patel
Resume Suresh Patel
Suresh J. Patel
 
Costof quality
Costof qualityCostof quality
Costof quality
Omnex Inc.
 
praveen
praveenpraveen
praveen
Praveen Mole
 
TCN_CV_R3ap
TCN_CV_R3apTCN_CV_R3ap
TCN_CV_R3ap
TAPESH NASKAR
 
Presentation Updating the Manufacturing Principles
Presentation Updating the Manufacturing Principles Presentation Updating the Manufacturing Principles
Presentation Updating the Manufacturing Principles
TGA Australia
 
Bharath Kumar Resume
Bharath Kumar ResumeBharath Kumar Resume
Bharath Kumar Resume
Bharath Kumar
 
Advanced Process Control for ARC
Advanced Process Control for ARCAdvanced Process Control for ARC
Advanced Process Control for ARC
anilkc12
 

Similar to EC plan 2014 Final Revision (20)

MVR BEFORE RAMP
MVR BEFORE RAMPMVR BEFORE RAMP
MVR BEFORE RAMP
 
Productivity Benchmarking in Spinning Mills
Productivity Benchmarking in Spinning MillsProductivity Benchmarking in Spinning Mills
Productivity Benchmarking in Spinning Mills
 
ENVOGUE - Energy Trending!
ENVOGUE - Energy Trending!ENVOGUE - Energy Trending!
ENVOGUE - Energy Trending!
 
Asik Ali Battery Production and Maintenance
Asik Ali Battery Production and MaintenanceAsik Ali Battery Production and Maintenance
Asik Ali Battery Production and Maintenance
 
dipankar bandyopadhyay_6787_GR_A
dipankar bandyopadhyay_6787_GR_Adipankar bandyopadhyay_6787_GR_A
dipankar bandyopadhyay_6787_GR_A
 
Apply model predictive control to reduce batch cycle time and increase consis...
Apply model predictive control to reduce batch cycle time and increase consis...Apply model predictive control to reduce batch cycle time and increase consis...
Apply model predictive control to reduce batch cycle time and increase consis...
 
Job description factory services engineer
Job description   factory services engineerJob description   factory services engineer
Job description factory services engineer
 
Peter cv
Peter cvPeter cv
Peter cv
 
Asia NOC Bridges Business-wide Performance Objectives and KPIs through an Adv...
Asia NOC Bridges Business-wide Performance Objectives and KPIs through an Adv...Asia NOC Bridges Business-wide Performance Objectives and KPIs through an Adv...
Asia NOC Bridges Business-wide Performance Objectives and KPIs through an Adv...
 
EECO2 GMP critical HVAC energy cost reduction
EECO2 GMP critical HVAC energy cost reductionEECO2 GMP critical HVAC energy cost reduction
EECO2 GMP critical HVAC energy cost reduction
 
An introduction to EECO2-Energy Efficiency Consultancy Limited
An introduction to EECO2-Energy Efficiency Consultancy LimitedAn introduction to EECO2-Energy Efficiency Consultancy Limited
An introduction to EECO2-Energy Efficiency Consultancy Limited
 
Smart Pharmaceutical Consulting - Lean Manufacturing of Pharmaceuticals
Smart Pharmaceutical Consulting - Lean Manufacturing of PharmaceuticalsSmart Pharmaceutical Consulting - Lean Manufacturing of Pharmaceuticals
Smart Pharmaceutical Consulting - Lean Manufacturing of Pharmaceuticals
 
Tolling group leader Positions
Tolling group leader PositionsTolling group leader Positions
Tolling group leader Positions
 
Resume Suresh Patel
Resume Suresh PatelResume Suresh Patel
Resume Suresh Patel
 
Costof quality
Costof qualityCostof quality
Costof quality
 
praveen
praveenpraveen
praveen
 
TCN_CV_R3ap
TCN_CV_R3apTCN_CV_R3ap
TCN_CV_R3ap
 
Presentation Updating the Manufacturing Principles
Presentation Updating the Manufacturing Principles Presentation Updating the Manufacturing Principles
Presentation Updating the Manufacturing Principles
 
Bharath Kumar Resume
Bharath Kumar ResumeBharath Kumar Resume
Bharath Kumar Resume
 
Advanced Process Control for ARC
Advanced Process Control for ARCAdvanced Process Control for ARC
Advanced Process Control for ARC
 

EC plan 2014 Final Revision

  • 1. 1
  • 2. Accelerate volume growth and gain NARTD share across all categories while reducing PoH + Opex and step-changing EBIT margin, capabilities and talent pool. Our Job Ticket
  • 3. Our Supply Chain Model 3 Demand Driven Quality Customer ServiceCost
  • 4. Supply Chain Goal • Deliver Quality Performance : BPQI >=95% , PCQI >=92%, MQI >= 85% • Drive Opex reduction by 6% basis excluding Depreciation Vs PY • Improve System Line Efficiency by 6% basis • Drive Production Compliance above 90% 4
  • 5. EAST CENTRAL SUPPLY CHAIN STRATEGIC FOCUS Strengthen Leadership Capability Development Functional Maintenance Structure and Routines Pre-emptive community mgt Process Management System Embed Quality and Safety Culture on the shopfloor
  • 7. RGB CAPACITY UTILISATION – EAST CENTRAL Key Assumption 1,083 1,083 1,750 1,250 1,500 833 0 1,500 0 0 100% 100% 80% 100% 100% 0% 0% 20% 0% 0% 45% 48% 40% 50% 52% 52% 52% 50% 52% 55% 53% 55% 52% 55% 58% OWERRI PORT HARCOURT EAST Utilisation Utilisation Total Owerri1 Owerri2 Owerri4 Total Total PHC1 PHC2 Total 2014 19,071,734 5,398,719 5,758,633 8,102,171 19,259,523 99% 10,849,092 6,923,565 8,640,609 15,564,173 70% 29,920,827 34,823,697 86% 1.04 2015 19,834,604 6,238,519 6,238,519 10,127,714 22,604,753 88% 11,283,056 7,200,507 9,139,105 16,339,613 69% 31,117,660 38,944,365 80% 1.04 2016 20,627,988 6,358,491 6,598,434 10,532,823 23,489,748 88% 11,734,378 7,615,921 9,637,602 17,253,523 68% 32,362,366 40,743,271 79% Sales Est Capacity Utilisation Line cap. (cph) Package Contrib. (%) Yearly SLE Sales Estimates Capacity Line cap. (cph) Package Contrib. (%) Yearly SLE CapacitySales Estimates Key Assumption 1,750 1,750 1,750 1,750 1,250 1,250 0 1,250 60% 100% 100% 40% 40% 0% 0% 60% 45% 45% 50% 50% 50% 50% 52% 50% 53% 53% 53% 53% Benin Enugu Central Utilisation AsabaSales Estimate Ben1 Ben2 Total ENU 1 ENU 2 Total 2014 17,787,512 8,794,197 8,723,691 17,517,889 102% 13,314,203 9,692,990 9,810,500 19,503,491 68% 31,101,716 37,021,379 84% 1.04 2015 18,499,013 9,771,330 9,692,990 19,464,321 95% 13,846,771 10,080,710 9,810,500 19,891,210 70% 32,345,784 39,355,531 82% 1.04 2016 19,238,973 10,357,610 10,274,570 20,632,180 93% 14,400,642 10,274,570 10,399,130 20,673,700 70% 33,639,616 41,305,880 81% UtilisationSales Estimates Utilisation prod CapSales Est Capacity Capacity Line cap. (cph) Line cap. (cph) Package Contrib. (%) Package Contrib. (%) Yearly SLE Yearly SLE
  • 8. Manufacturing KBIs 2012 FY 2013 FY 2013 BP Vs PY Vs BP Manufacturing Cost Per Case 176.0 173.8 143.2 SLE 51.9% 41.5% 58.0% Concentrate Yield 99.1% 98.9% 99.4% Sugar Yield 99.0% 98.8% 99.2% Crown Wastage 1.6% 1.7% 0.7% Bottle Breakages 0.62% 0.53% 0.57% CO2 Yield 55.5% 57.8% 60.0% LOB/Kwhr 13.0 13.2 15.1 PHC/LOF Boiler 13.4 14.8 12.4 Caustic Usage 1.6 1.6 1.5 Production Compliance 60% 75% 80%
  • 9. Quality and Sustainability KBIs 2012 FY 2013 FY 2013 BP Vs PY Vs BP SAFETY: LTA 12.0 8.0 0.0 SAFETY: FAI 127.0 129.0 64.0 SAFETY: FATALITY 0.0 1.0 0.0 BPQI 92.5% 89% 95% PCQI 85.6% 83% 91% Date Code 95.8% 93.0% 97.0% Net Content 93.4% 94.0% 96.8% PDQI 78.0% 83.5% 83.0% Water Usage Ratio 2.73 2.13 2.59 Energy Usage Ratio 0.60 0.56 0.53 Solid Waste Ratio 18.47 23.52 17.45
  • 10. 2013 – Key Learnings SYSTEM LINE EFFICIENCY QUALITY AND SUSTAIN- ABILITY COST LEADERSHIP  Inadequate operating and maintenance skill  Problem Solving lengthy due to skill Team Management weak OPL driven mainly by Forlift availability and reliability Glass returnability could be better managed Spares management still challenging Better line overhaul execution but preparation needs improvement Better Line scheduling can help utilisation PPE compliance still a challenge Incoming material inspection inadequate Shopfloor involvement in quality inspection Ownership for on-line quality control equipment operation and maintenance Use Process monitoring and control to drive quality improvement GMP/GHK standard improvement Audit CAP review inadequate Toolbox Talk Execution Inadequate Pre approval process key in controlling casual usage and overtime Focus on energy projects Regular reconciliation on area/equipment basis helps in Yields and breakages control Better and Timely equipment maintenance helps control business loss Plant level cost review on weekly basis Inadequate Quality control lead to high business loss due to manufacturing defects Ineffective incoming glass inspection both from Trade and new glass led to hogh cost of glass write-off
  • 11.
  • 12. 12 1. KHS line rebuild 2. Execute RGB Lines Overhaul Plan 3. End of Line automation in Benin(Palletiser) 4. Owerri Lines 1 & 2 Upgrade 5. Leverage SAP PM and EATB Kaizen 6. Leverage GPIT and TNT Support 7. Ultra Glass Injection Impact 8. Volume Allocation in Central(benin to Enugu) during Peak Season 9. Minimum Run Size Adherence and Speed Loss Eliminination 1. Leverage New PHC PET Line 2. Benin PET line Overhaul 3. Juice Line 4 TPMS 4. Owerri PET EvA Line overhaul 5. Leverage on new end of line equipments on Benin Line 6 6. Leverage SAP PM and EATB Kaizen 7. Leverage GPIT and TNT support for Benin and Owerri 8. Transition to 48h CIP on Eva line 9. Reinforce Incoming inspection of packaging materials e.g pallets, films etc 1. Effective glass management 2. Enforce Glass Staging across all Plants 3. Forklift Management(TAT and Maintenance) 4. Enforce EATB PM across all Plants – Weekly and Monthly for STLs and LM 5. Line schedule optimisation 6. Mixer Operator Assessment and Skill Upgrade 1. SMED Implementation across all Plants 2. Restoration of CIP system into Auto Mode 3. Synchronisation of CIP/Changeover Timing RGB SLE Up By 3% OWP SLE Up By 6% OPL Down By 50% CIP/ Changeover Time reduction PRODUCTIVITY
  • 13. 1313 1. Leverage Juice line TPMS 2. Benin PET Filler Overhaul Impact 3. Benin Line 1 and 2 filler overhaul 4. Mixer Overhaul and operator training 1. Tracking and reconciliation on shift basis 2. Leverage RGB line overhauls 3. Ultra Glass Introduction Impact 4. Proper Glass sorting process at Plant and Depot 5. Enforce Proper CIP/Changeover practices as it relates to Washer 1. Weekly Pre approval process 2. Weekly cost review and CAP 3. Leverage SLE improvement to minimise run days 4. Energy management /Load Shedding during Non Production Period 5. Implement Top 10 menergy sevres to reduce consumption 6. UPS Capacity increase and introduction in relevant plants 1. Effective sorting in trade 2. Implement proper glass handling practices in Plant and Depot Reduce Manufacturin g Defects <PY Reduce Bottle breakages <0.5% Overtime , Casual and Energy Cost Management in line with BP Scuff Glass Managemen t Drive Manufacturing Cost Improvement Through Business Loss and Overhead Reduction COST LEADERSHIP
  • 14. 1414 1. Coding Machine Upgrade and Overhaul 2. Effective Power Protection in Place 3. Implement OEM Standards for operation 4. Operator Involvement in On-line Quality control(15minutes check by filler operator) 5. Installation of Laser coders on all PET lines 6. Fully functional standby coders on all RGB lines 1. Implement revised Vent tube management 2. Filling valves and lift cylinders validation and Maintenance 3. Operator Involvement in On-line Quality control 4. Check mat Functionality Audit and Access Control 5. Robus incoming inspection and adherence to 1000cases run for new glass 1. Enugu Lines fully ASEBI 2. Miho Asebi Maintenance Schedule compliance 3. Mixer Operator Training 4. Implement Effective DO Management: Daily tracking, Review and implement CAP for out of limits 5. Regular Crimp checks and control by Filler operator 1. Regular System audit action plan tracking and review 2. Biannual Compliance Self assessment 3. Yearly Kore Standards Training/Refresher(Virtual Factory) 4. Process monitoring and control across all plants 5. B2B rollout in EC Date Code Net Content Carbonation Quality Systems Compliance Drive Quality Through Shopfloor Engagement and Accountability QUALITY
  • 15. 1515 1. Daily random PPE Compliance by PMs 2. Daily Tool Box Talk in SBT and weekly in PM meetings 3. Implement weekly Hazard spotting and correction 4. Enforce Hot work permit 5. Ensure all Machine guarding fully functional 6. Enforce Energy isolation(LOTO) in plants 1. Fully functional Fire protection: Extinguishers and Hydrant system 2. Enforce Drill Schedule 3. Fire Alarm Systems Fully functional Implement Preventive Systems Implement Protection Systems Drive Safety and Environmental ComplianceThrough Zero Tolerance to Non Compliance and standards implementation Safety Regulatory Compliance 1. Regular System audit action plan tracking and review 2. Biannual Compliance Self assessment and Corrective action Planning SUSTAINABILITY – SAFETY AND ENVIRONMENT 1. Restore all Plants ETP to full functionality 2. Ensure all water meters are fully functional and calibrated 3. Implement agreed WUR and SWR projects in all plants 4. Drive implementation of key energy reduction initiates eg UPS Enugu, Gas Generator sets for owerri Environmental Systems Compliance
  • 16. Capability Development Top Key issues Line Management Quality Knowledge especially on the shop floor Preventative Maintenance  Deep Diving Skill Key Initiatives Rollout of EAtB across East and Central Plants Technical Training for Key Equipment operator - Mixer Production, Quality Assurance, Plant Engineer Development Programme Simplified BQAT to the shop floor Levarage New PHC PET CSD Line to Upscale technical skill All PMs Enrolled in Accenture Supply Chain Academy Leverage TTC Graduate Trainee  Line Manager Development Curriculum B2B Rollout across East Central
  • 17. Sales Volume: 87.05MUCS DIFOTAI: 90% SLE: 54.4% Production Compliance: 85% Manufacturing Cost, CPC: =N=152.51/Case Concentrate Yield: 99.32% Sugar Yield: 99.12% Business Loss: 50% below PY MQI: 84% BPQI: 94.5% PCQI: 92% Date Code: 97% FAI: 50% below PY LTA: 0 Fatality: 0 WUR 2.50 EUR 0.48 Customer Preference Cost Leadership Consumer Relevance Community Trust People & Capability Capability Development: 85% IDP Compliance Quality and Safety Audits: 100% Compliance EATB Audits : All 4 Plants Certified EC 2014 PICTURE OF SUCCESS