Manufacturing KPI Review by CEO-Aug Final 10

1

MANUFACTURING KPI REVIEW AUGUST 2010

Contents 2

Strategic KPI’s



SKU Availabi Availability lity 3 at Ag Agent level le vel SB Cost Coent st per dozen doze n 8 

Consumer Quality Index Capacity 

Utilizat Utili zation ion BH) Technical & ( Technological Innovations

11 15 18

Operational KPI’s



Divisional Overheads Outstanding Interna Inte rnal l Audi Audit t Issues No MNC at External Audits

20

Hygiene Aud Hygiene Audit it Score

38





36

35

Management Managem ent of Knowledg ledge Pool Know Turno Tu rnover vere of Key People Training & development PEAP Completio Completion n 

  Waste Reduction Raw Mate Material rial cost reductio ction n Sale Sal e redu of Exc Excess ess Co2

39 39 39

Strategic KPI – 1. SK Strategic SKU U availability 3

Efficiency Measurement



KPI



SKU availability at agents agents

4

Package ged d volume FG Inventor Inventory y Forecasting (Agents Agents+LBCPLC LBCPLC ) Inventory accuracy Cover days

12 12 13 13 14 15 16

Below TG

FG Inventoryholding cost (Also reflecte reflected d by the volume)

17

In1. venSKU tory (dAVAILABILITY ays) as at 1 st of each each mont month h calc calcul ulat ated ed Strategic KPIFG–Inv 1.1 SKU availability & inventory holding 4

base based d o

+ LBCL) taken ntsStrategic as –the and calculated the KPI 1. standard SKU AVAILABILITY

1.2 SKU Availability-FG Inventory 5

(%) above or below target .

Strategic KPI – 1. SKU AVAILABILITY Overall RD 1.3 SKU Availability-Forecast Vs Sales 6

sales -2.37%

Strategic KPI – 2. SB Raw Material Cost 7

Efficiency measure

KPI





SB Raw Material cost per dozen

Below TG

9

Malt Price Rice Price Sugar Price Usage Variance

12 12 13

Strategic KPI – 2. SB Raw Material cost 2.1 Direct Raw Material Prices 8

Strategic KPI – 2. SB Raw Material cost 2.2 SB Cost/hl for each SKU 9

Strategic KPI – 2. SB Raw & Packaging Material cost 2.3 Usage Variance 10

Tgt. 2425Rs/hl

Strategic KPI – 3. Consumer Quality Index

11

Efficiency measure

KPI





Consumer Quality Index

Below TG

14

Brewing Quality Packaging Quality Index Index Utility Quality Raw Mat. quality Index Index

12 12 12

Quality Indexes are the internal measurements of qual Strategic KPITechnical – 3. Consumer Quality Index All the indexes are calculated OOS as a % of samples analyzed . 3.1 Divisional Technical Quality Indexes 12

Strategic KPI – 3. Consumer Quality Index 3.2 Brand Wise Quality Indexes 13

Strategic KPI – 3. Consumer Quality IndexIndex 3.3 Consumer Quality Index 14

not ready

Strategic KPI – 4. Capacity Utilization

15

Efficiency measure

KPI





Capacity Utilization

Below TG

4

Brewing Capacity Bottling Capacity Uti. . Uti Canning Capacity Uti.

16 16 16

Opportunity loss due to shortages Cost of loss in Market share

Strategic KPI – 4. Capacity Utilization 4.1 Brewing, Bottling & Canning 16

Only average loads Strategic KPI – 4. Capacity Utilization 4.2 Utility plants 17

are taken for these calc

Strategic KPI – 5. Technical Innovations

18

Efficiency measure

KPI





Technical Innovations

Below TG

4

Number implemented

12 12

Estimated Savings per annum

CSS Strategic KPI – 5. Technical Innovations 5.1 Successful implementations 19

CSS Plant

plant

& SB Recipe

PROJECT KPI– 1 20

Efficiency measure

KPI





KEY Projects

Below TG

Rate of completion

Savings

Strategic KPI – 5. PROJECTS (contd.) Some payments made as advances have 5.2 Project Status 21 186,000,000 August 2010

36,300,000 Aug 2010

22,000 Pending 9,849,000 August 2010

86,163,000

Augu

2010

not yet been settle

Strategic KPI – 5. PROJECTS 5.2 Project Status 22 On ROI basis Sept 2010

 – continuous activity .  – continuous activity

Operational KPI – 1. Divisional Overheads 

Efficiency measure

KPI





Divisional Overheads

Product Losses Overtime (Extract) as a % of total working time Utility consumption Bottle Breakage Packaging Efficiency Spare parts inventory

Below TG

22 27 26 33

Divisional Overhead Budget Vs 28 Cost of Spillages actual People variable cost Spare parts inventory

Operational KPI – 1.1 Divisional Overheads (Brewing) 1.1.0 Divisional Overhead actual vs. budgeted (cumulative) 24

Operational KPI – 1.1 Divisional Overheads (Brewing) 1.1.1 Product Losses (Extract basis) 25

Operational KPI – 1.1Divisional Overheads (Brewing) 1.1.2 Cost of Spillage 26

ac ag ng 1.2.0 Divisional Overhead actual vs. budgeted (cumulative) 27

perat ona – . v s ona ver ea s (Packaging) 1.2.1 Packaging Loss (Volume basis) 28

perat ona – . . v s ona ver ea s (Packaging) 1.2.2 Packaging & Line Efficiency 29

(Packaging) 1.2.3 Packaging Line – Internal bottle breakages 30

Operational KPI – 1.2 Divisional Overheads (Packaging) 1.2.4 Packaging Spillage 31

pera ona – . v s ona ver ea s (Engineering) 1.3.0 Divisional Overhead actual vs. budgeted 32

pera ona – . v s ona ver ea s (Engineering) 1.3.1 Furnace fuel consumption 33

pera ona – . v s ona ver ea s (Engineering) 1.3.2 Electricity Consumption 34

perat ona – . v s ona (Engineering) 1.3.3 Water Consumption 35

ver ea s

pera ona – . v s ona ver ea s (Engineering) Increase is as a result of preparations 1.3.4 Engineering Spares inventory 36

for the An

Operational KPI – 1.4 Divisional Overheads (Quality Assurance) 1.4.0 Divisional Overhead actual vs. budgeted 37

Operational KPI audit issues

– 2. & 3. Pending

38

Efficiency measure

KPI





Pending Audit NC

Pending Internal NC Pending External NC

Below TG

Operational KPI – 2 Pending Internal audit findings No Pending 3 Pending External audit findings 39

issues

Operational KPI Score

– 4 Hygiene Audit

40

Efficiency measure

KPI





Hygiene Audit Score

Below TG

Brewing Packaging Engineering Quality Engineering Stores