The document summarizes a simulation project conducted by Britvic Soft Drinks to model operations at their Leeds factory and warehouse after installing a new high-speed PET production line and expanding warehouse capacity. The simulation aimed to answer questions about vehicle traffic, gate throughput, trailer parking needs, loading bay requirements, forklift needs, and warehouse flows. Key learnings included identifying pinch points in traffic flows and validating the number of trailer parking spaces and loading bays needed. Next steps involve further enhancing the Leeds model with additional production line and automation details and developing models for other Britvic sites.

1. Neil Brinkman, David Rice
Britvic Soft Drinks
Leeds factory & warehouse simulation

2. Agenda
• Introductions
• Introduction to Britvic
• Simulation overview
• Project overview
• Findingssummary

3. Making life’s everyday moments
more enjoyable

4. Leading branded soft drinks business
More than 30 brands
More than 30 brands

5. Strategy
Being the
benchmark
integrated branded
soft drinks
business for both
PepsiCo and our
own brands
in GB & Ireland
Fully exploiting
global category
opportunities in
Kids, Family and
Adult
Creating a
simple focused
operating model,
empowering our
people and
matching
resource and
capability to the
opportunities
Being a trusted
and respected
member of the
communities in
which we operate

6. Leading branded soft drinks business
£1,321.9m
Group revenue
Source: Britvic Plc Annual report 2013

7. Leading branded soft drinks business
3,300
employees

8. Leading branded soft drinks business
2,066.9m
litres per year
Source: Britvic Plc Annual report 2013

9. Strong track record and growing
No2 in British branded carbonate soft
drinks
in Irish branded soft drinks
in French syrups
Britvic became PepsiCo bottler in UK
No2
No1
1987
Source: Nielsen/Britvic Soft Drinks report 2013

10. Owned brands in UK
Franchised brands in UK

11. Where we operate - GB
Hemel Hempstead
Solihull
Factories
Offices
1850 employees
Lutterworth
Distribution
Norwich
8 lines PET
Beckton
4 lines Plastic (PET)
Rugby
6 lines Can,
PETandAseptic
Leeds
3 lines Glass and Bag in box
1 PETline
640 products
Where we operate

12. The simulation challenge

13. Network simulation:
• Have the ability to model our network
• Supporting business decisions
• Capital investment planning
• What’s made where
• Storage requirements
• Inventory policy review
• Benefits cases
• Centre of gravity analysis
• Capacity planning
Having agreed the network solution a more detailed analysis is required by location.

14. Skyfall – Leeds New High Speed PET line
• New high speed PET production line
optimised at 36K bottles per hour
• New finished goods warehouse
• New loading bays to support increased
inbound materials and outbound loads
• New trailer park
• Line capable of producing 1litre to 3 litre
packs
• Line started Monday 9th November

15. What were the questions?
• Vehicle movements around the site
• Gatehouse throughput
• Trailer parking – how many?
• Loading bays – how many?
• Internal warehouse movements
• Number of FLT’s required
• Traffic volumes – key pinch points
• Warehouse flows

16. Leeds - Skyfall New loading bays
New warehouse
New staff & visitor parking
New trailer parking
New production Line
Existing production lines (3)
Gatehouse

17. Key learnings
• Vehicle movements around the site
• Gatehouse throughput
• Site could work, however we have designed the trailer park to enable easier access
• Trailer parking how many?
• 30-35 trailer parking spaces, this is to ensure we cover off weekend pre loading
• Loading bays – how many?
• 6 loading bays would work
• Internal warehouse movements
• Number of FLT’s required
• Confirmed the number FLT’s in each area
• Traffic volumes – key pinch points
• Key H&S risk points identified, 1 way system put in place
• Warehouse flows
• Automation flows started to be considered

18. Beginning to see the output from the modelling…
One way system out into the loading bayTraffic flows in to the warehouse

19. Beginning to see the output from the modelling…
Warehouse starting to take shapeLoading bays – nearly ready for use

20. Simulation key points / next steps :
Key learnings :
• Great way to bring changes to life
• Key to gain buy in from the sites – ensure you can model the “as is”
• Be clear on the questions you are seeking to solve –
• Good guidance from Lanner, as we wanted answers to questions that didn’t exist!!!
Next steps :
• Further enhancement of the Leeds model
• Refine the modelling as we understand the operation post go live
• 2nd new line announced
• Further automation
• Development of models for other sites – further investment at Rugby site

21. Any questions?