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Enjoy Manufacturing Report July 2010
1 – Enjoy Plant Headcount
2 – Salary Cost / ton
3 – Actual Industrial Expenses Vs Budget
4 – Raw Milk Received
5 – Qty in Ton 2010 Vs 2009
A – Tetra pak
B – Glass Juice
C – Yogurt
6 – Cost Control Project
A – Filling M/cs Efficiency & utilization
B – Power consumption
C – Spare Parts
D – CIP
E – Wastage
7 – New Project
8 – QC Report – Returns
9 – Pending works
47
135
62 61
81
386
139
44
130
46 51
73
344
123
46
142
42 50
72
352
144
55
154
44
54
79
386
223
54
155
44
53
81
387
177
0
50
100
150
200
250
300
350
400
450
Adminstration Production Engineering QC Warehouses Total Casual
2009 Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10 Jul-10
1 – Enjoy Plant Headcount
1 – Casual staff was 141 which is less last month by 36 persons Vs 120 as a target
2 – Regarding staff turn over status during this month, in/out = 22 employed / 2
resigned - YTD in/out = 70/30
3 – Administration staff increase by 11 than last month
186 176 147 141 131 128 107 141
122
170
146
136
122
131
139 137
13 12 13 14 13 12 12 13
0
20
40
60
80
100
120
140
160
180
200
Jan.10 Feb.10 Mar-10 Apr-10 May-10 Jun-10 July10 Total
budget Cost / ton Actual Cost/ton Tons / one labor
2 – Salary Cost / ton
1 – The total over time for July = 97 768 which represent 12.5 % of total salary
2 – Labour salary = 139 L.E. / ton During this month
3 – Actual Industrial Expenses Vs Budget
2,723,609
2,660,700
2,926,652
3,325,511
3,414,917
3,420,108
3,787,086
4,206,306
4,016,759
3,736,724
3,494,062
3,505,727
2,079,377
2,412,543
2,590,856
2,473,189
2,873,060
3,660,368
3,021,395
644,232
248,157
335,796
852,322
541,857
-240,260
765,691
-500,000
0
500,000
1,000,000
1,500,000
2,000,000
2,500,000
3,000,000
3,500,000
4,000,000
4,500,000
Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10 Jul-10 Aug-10 Sep-10 Oct-10 Nov-10 Dec-10
Budget 2010 Actual 2010 Diff. in L.E.
1 – The total Saving YTD is 3 147 795 L.E. and saving during this month
was 765 691 L.E.
Expenses in L.E./Ton
342.5
431.4
388.2
359.8
394.3
459.7
475.6
408.2
0.0
50.0
100.0
150.0
200.0
250.0
300.0
350.0
400.0
450.0
500.0
Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10 Jul-10 YTD
Expenses budget L.E./ton
1 – YT D industrial cost / ton 408 L.E.
2,080
2,020
2,508
2,877
2,789
2,296 2,288 2,273
2,618
2,802
2,892
2,785
2,015
1,930
2,142
3,303
2,524
2,742
2,210
0
500
1,000
1,500
2,000
2,500
3,000
3,500
Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10 Jul-10 Aug-10 Sep-10 Oct-10 Nov-10 Dec-10
Plan Actual
4 - Raw Milk Received
1 – YTD, Dina farm supplied = 70 ton /day which represent 89 % of the total milk
received
2 – YTD, milk received represent 56 % of the annual target
3 – the actual milk received during this month is less than target due to having
enough stock of finished product
3,854
4,599
3,859
3,664
4,466
4,960
2,508
5,175
5,153
5,335
4,924
4,767
6,071
5,592
6,674
6,657
7,286
7,963
6,000
5,339
4,702
6,122
5,114
5,315
0
2,000
4,000
6,000
8,000
10,000
12,000
Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10 Jul-10 Aug-10 Sep-10 Oct-10 Nov-10 Dec-10
2009 in ton Plan 2010 in ton Actual 2010 %
5 - Qty in Ton 2010 Vs 2009
1 – YTD, Total Production = 72 835 tons which represent 84 % of the total yearly
target
2 – the reason for less productivity during last 6 months was due to :
A – Long time to receive spare parts and no enough TP staff for technical support
B – Utilities break down due to hot season
C – High turn over of technical staff and postponed the TP training
2,325
2,325
590
2,140
695
1,082
2,161
503
1,633
541
1,808
1,951
438
2,069
531
825
1,579
191
2,585
230
-
500
1,000
1,500
2,000
2,500
3,000
Milk 1 L Juice 1 L Milk & Flavoured 200 ml Juice 200 ml Fino Milk
Max Capacity in Ton Plan inTon Modified plan in Ton Actual in Ton
5 – A – Tetra pak - Plan Vs Actual Finish Product
in Ton
1 – Production of 200 ml reach to 65 % of the max capacity
2 – Total TP Production represent 99 % of sales forecast
5 – B – Glass Juice - Plan Vs Actual Production
in Ton
450
590
500
297
769
323
505
596
180
356
405
186
-
100
200
300
400
500
600
700
800
900
Glass 1 L Glass 250 ml x 12 Glass 250 ml x 24
Max capacity in Ton Plan in Ton Modified plan in Ton Acutal production in Ton
1 - Total Glass Juice Production represent 68 % of the max available capacity
and represent 74 % of Modified Sales forecast
5 – C – Yogurt
Plan Vs Actual in Ton
800
633
931
799
0
100
200
300
400
500
600
700
800
900
1,000
Total
Max capacity in ton Plan 2010 in ton Modified plan 2010 in ton Actual 2010 in ton
1 - Total Yoghurt Production represent 100% of the max available capacity
and represent 126 % of sales forecast as a result of changing target due to market
demand
50
251 230
343
280
108
45
54
171
100
78
623
91
110
106
120
23
281
162
119 73
92
520
297
139
66 74
126
39
0
100
200
300
400
500
600
700
800
TBA/8 L1 TBA/8 L2 TBA/19 L4 TBA/19 L5 TBA/22 L6 TFA/3 L7
Production time Equipment stop Other Stop Time outside production phase Idel time
1 - Tetra Fino could not archive the target due to :
A – Bottle neck of process equipment
B – No need to produce FC milk which should run at the same time with 1 litter m/c
2 – Slim cap for Line #1 should be replaced by recap due to slim cap could not be used for export
and Al-Misrieen products and that is one of the reason to limitation of production time
6 – Cost Control Projects
A – TP Filling m/cs Working hrs
6 – Cost Control Projects
A – Filling M/cs Efficiency
52%
92%
80% 80% 82%
98%
78%
74%
84% 86% 84%
67%
74% 73%
68%
75%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
TP L#1-1L TP L#2-1L TP L#3-
200ML
TP L#4-
200ML
TP L#5-
200ML
TP L#6-
500ML
TP L#7-
200ML
Total TP
M/cs
Erica M/c Formaseal
M/C
Total
Yogurt m/c
Glass L#1-
250 ML
Glass L#1-
1L
Glass L#2- 1
L
Total Glass
M/Cs
Total Plant
M/Cs
TP L#1-1L TP L#2-1L TP L#3-200ML TP L#4-200ML TP L#5-200ML TP L#6-500ML
TP L#7-200ML Total TP M/cs Erica M/c Formaseal M/C Total Yogurt m/c Glass L#1-250 ML
Glass L#1- 1L Glass L#2- 1 L Total Glass M/Cs Total Plant M/Cs
• Remarks:
• Wedge m/cs produced 3 types of product during this month till complete using the package materials
6 – Cost Control Projects
B – Power consumption
96 97 103 109 109
98
141
107
71
80 75 74 74
66
92
75
29
40
30 31 35 34
40
34
0
20
40
60
80
100
120
140
160
Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10 Jul-10 YTD
Qty / ton Total power Cost L.E. / ton Cost/1000 packs
• The total standard power cost/ton=55 L.E
• The total standard power cost/ 1000 pack=25 L.E
6 – Cost Control Projects)
C – Spare Parts
78
63
58
54
64
54 52
60
28 27
23
20
29 28
25 26
20 20 20 20 20 20 20 20
0
10
20
30
40
50
60
70
80
90
Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10 Jul-10 Total
spare parts Cost L.E./ ton Actual cost L.E./1000 pack Standard cost L.E./1000 pack
• The total standard spare parts cost/ 1000 pack = 20 L.E
And still waiting confirmation from TP Co.
6 – Cost Control Projects
D - CIP
1.9
1.6
1.3 1.3
1.2 1.2 1.1
1.5
1.3
3.2
2.9
2.2
2.3 2.3 2.2
2.0
2.7
2.4
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
Dec-09 Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10 Jul-10 YTD
Kg Acid / ton product Kg Soda / ton product
6 – E – Wastage in L.E.
2.36%
1.60%
1.20%
2.40%
0.00%
0.50%
1.00%
1.50%
2.00%
2.50%
3.00%
TP section Glass section Yogurt section Total
Wastage Value %
Wastage Value %
7 – New Project ( Cost & Time frame )
8 – QC Report – Returns
• Reason for Sales return qty in Cartons:
Product Sales return Qty Due
to bad handling in
carton
Sales return Qty Due
to Expire date
Manufacturing
drained
&reprocessed in
carton
Total
Milk 1 L 1 158 172 45 1 375
Flavoured Milk 200 ml 529 204 1 734
Milk Joy 637 174 0 811
Juice 1 L 673 21 40 698
Juice 200 ml 61 4 0 65
Glass 1 L 120 9 0 129
Glass 250 ml 858 38 4 900
Yoghurt ( cups ) 846 2 482 0 3328
Yoghurt ( Gallons – 4 kg ) 277 4 608 0 4 885
Samples and Lab Analysis
1 – All Production was released after QC approval this month
2 – No market complain about taste ( approved recipes )
3 – 26 costumer complaints during this month , most of them as a result of Recap of one liter
4 – No Spoil ( un-sterility ) during this month
9 – Pending* achieving works
Pending Works :
1 – The main issue for Environment project, supply Government
water and sewage pipe line ( waiting for fund )
2 – Repairing Electric generators, synchronization unit and interconnection
with new electric room ( waiting for fund )
3 – Complete overhauling for main pasteurize plant – Waiting TP reply
4 – Install the new RO plant – 15 / 5 / 2010
5 – Install the drink unit received from Al-Misrieen Waiting TP reply
6 – Upgrade of Old flex (UHT) – post bond till arrange between Enjoy and TP
7 – Water collection for all processing equipment – waiting quotations
8 – Fire alarm system ( waiting for fund )
11 – milk tanker local quotations were received and waiting overseas quotations
Achieving Works :
1 – TWF filling m/c start production this month
2 – Boilers overhauling were completed
3 – Spoiling product room was completed with new well and m/c was
transferred
4 – More than 3000 wooden pallets were produced from scrape wood
5 – New extension project, waiting final offer after complete technical discussion
6 – Al-Zomer store was completed and ready to sore finish product

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Plant Yearly Report 2010 (2)

  • 1. Enjoy Manufacturing Report July 2010 1 – Enjoy Plant Headcount 2 – Salary Cost / ton 3 – Actual Industrial Expenses Vs Budget 4 – Raw Milk Received 5 – Qty in Ton 2010 Vs 2009 A – Tetra pak B – Glass Juice C – Yogurt 6 – Cost Control Project A – Filling M/cs Efficiency & utilization B – Power consumption C – Spare Parts D – CIP E – Wastage 7 – New Project 8 – QC Report – Returns 9 – Pending works
  • 2. 47 135 62 61 81 386 139 44 130 46 51 73 344 123 46 142 42 50 72 352 144 55 154 44 54 79 386 223 54 155 44 53 81 387 177 0 50 100 150 200 250 300 350 400 450 Adminstration Production Engineering QC Warehouses Total Casual 2009 Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10 Jul-10 1 – Enjoy Plant Headcount 1 – Casual staff was 141 which is less last month by 36 persons Vs 120 as a target 2 – Regarding staff turn over status during this month, in/out = 22 employed / 2 resigned - YTD in/out = 70/30 3 – Administration staff increase by 11 than last month
  • 3. 186 176 147 141 131 128 107 141 122 170 146 136 122 131 139 137 13 12 13 14 13 12 12 13 0 20 40 60 80 100 120 140 160 180 200 Jan.10 Feb.10 Mar-10 Apr-10 May-10 Jun-10 July10 Total budget Cost / ton Actual Cost/ton Tons / one labor 2 – Salary Cost / ton 1 – The total over time for July = 97 768 which represent 12.5 % of total salary 2 – Labour salary = 139 L.E. / ton During this month
  • 4. 3 – Actual Industrial Expenses Vs Budget 2,723,609 2,660,700 2,926,652 3,325,511 3,414,917 3,420,108 3,787,086 4,206,306 4,016,759 3,736,724 3,494,062 3,505,727 2,079,377 2,412,543 2,590,856 2,473,189 2,873,060 3,660,368 3,021,395 644,232 248,157 335,796 852,322 541,857 -240,260 765,691 -500,000 0 500,000 1,000,000 1,500,000 2,000,000 2,500,000 3,000,000 3,500,000 4,000,000 4,500,000 Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10 Jul-10 Aug-10 Sep-10 Oct-10 Nov-10 Dec-10 Budget 2010 Actual 2010 Diff. in L.E. 1 – The total Saving YTD is 3 147 795 L.E. and saving during this month was 765 691 L.E.
  • 5. Expenses in L.E./Ton 342.5 431.4 388.2 359.8 394.3 459.7 475.6 408.2 0.0 50.0 100.0 150.0 200.0 250.0 300.0 350.0 400.0 450.0 500.0 Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10 Jul-10 YTD Expenses budget L.E./ton 1 – YT D industrial cost / ton 408 L.E.
  • 6. 2,080 2,020 2,508 2,877 2,789 2,296 2,288 2,273 2,618 2,802 2,892 2,785 2,015 1,930 2,142 3,303 2,524 2,742 2,210 0 500 1,000 1,500 2,000 2,500 3,000 3,500 Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10 Jul-10 Aug-10 Sep-10 Oct-10 Nov-10 Dec-10 Plan Actual 4 - Raw Milk Received 1 – YTD, Dina farm supplied = 70 ton /day which represent 89 % of the total milk received 2 – YTD, milk received represent 56 % of the annual target 3 – the actual milk received during this month is less than target due to having enough stock of finished product
  • 7. 3,854 4,599 3,859 3,664 4,466 4,960 2,508 5,175 5,153 5,335 4,924 4,767 6,071 5,592 6,674 6,657 7,286 7,963 6,000 5,339 4,702 6,122 5,114 5,315 0 2,000 4,000 6,000 8,000 10,000 12,000 Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10 Jul-10 Aug-10 Sep-10 Oct-10 Nov-10 Dec-10 2009 in ton Plan 2010 in ton Actual 2010 % 5 - Qty in Ton 2010 Vs 2009 1 – YTD, Total Production = 72 835 tons which represent 84 % of the total yearly target 2 – the reason for less productivity during last 6 months was due to : A – Long time to receive spare parts and no enough TP staff for technical support B – Utilities break down due to hot season C – High turn over of technical staff and postponed the TP training
  • 8. 2,325 2,325 590 2,140 695 1,082 2,161 503 1,633 541 1,808 1,951 438 2,069 531 825 1,579 191 2,585 230 - 500 1,000 1,500 2,000 2,500 3,000 Milk 1 L Juice 1 L Milk & Flavoured 200 ml Juice 200 ml Fino Milk Max Capacity in Ton Plan inTon Modified plan in Ton Actual in Ton 5 – A – Tetra pak - Plan Vs Actual Finish Product in Ton 1 – Production of 200 ml reach to 65 % of the max capacity 2 – Total TP Production represent 99 % of sales forecast
  • 9. 5 – B – Glass Juice - Plan Vs Actual Production in Ton 450 590 500 297 769 323 505 596 180 356 405 186 - 100 200 300 400 500 600 700 800 900 Glass 1 L Glass 250 ml x 12 Glass 250 ml x 24 Max capacity in Ton Plan in Ton Modified plan in Ton Acutal production in Ton 1 - Total Glass Juice Production represent 68 % of the max available capacity and represent 74 % of Modified Sales forecast
  • 10. 5 – C – Yogurt Plan Vs Actual in Ton 800 633 931 799 0 100 200 300 400 500 600 700 800 900 1,000 Total Max capacity in ton Plan 2010 in ton Modified plan 2010 in ton Actual 2010 in ton 1 - Total Yoghurt Production represent 100% of the max available capacity and represent 126 % of sales forecast as a result of changing target due to market demand
  • 11. 50 251 230 343 280 108 45 54 171 100 78 623 91 110 106 120 23 281 162 119 73 92 520 297 139 66 74 126 39 0 100 200 300 400 500 600 700 800 TBA/8 L1 TBA/8 L2 TBA/19 L4 TBA/19 L5 TBA/22 L6 TFA/3 L7 Production time Equipment stop Other Stop Time outside production phase Idel time 1 - Tetra Fino could not archive the target due to : A – Bottle neck of process equipment B – No need to produce FC milk which should run at the same time with 1 litter m/c 2 – Slim cap for Line #1 should be replaced by recap due to slim cap could not be used for export and Al-Misrieen products and that is one of the reason to limitation of production time 6 – Cost Control Projects A – TP Filling m/cs Working hrs
  • 12. 6 – Cost Control Projects A – Filling M/cs Efficiency 52% 92% 80% 80% 82% 98% 78% 74% 84% 86% 84% 67% 74% 73% 68% 75% 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% TP L#1-1L TP L#2-1L TP L#3- 200ML TP L#4- 200ML TP L#5- 200ML TP L#6- 500ML TP L#7- 200ML Total TP M/cs Erica M/c Formaseal M/C Total Yogurt m/c Glass L#1- 250 ML Glass L#1- 1L Glass L#2- 1 L Total Glass M/Cs Total Plant M/Cs TP L#1-1L TP L#2-1L TP L#3-200ML TP L#4-200ML TP L#5-200ML TP L#6-500ML TP L#7-200ML Total TP M/cs Erica M/c Formaseal M/C Total Yogurt m/c Glass L#1-250 ML Glass L#1- 1L Glass L#2- 1 L Total Glass M/Cs Total Plant M/Cs • Remarks: • Wedge m/cs produced 3 types of product during this month till complete using the package materials
  • 13. 6 – Cost Control Projects B – Power consumption 96 97 103 109 109 98 141 107 71 80 75 74 74 66 92 75 29 40 30 31 35 34 40 34 0 20 40 60 80 100 120 140 160 Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10 Jul-10 YTD Qty / ton Total power Cost L.E. / ton Cost/1000 packs • The total standard power cost/ton=55 L.E • The total standard power cost/ 1000 pack=25 L.E
  • 14. 6 – Cost Control Projects) C – Spare Parts 78 63 58 54 64 54 52 60 28 27 23 20 29 28 25 26 20 20 20 20 20 20 20 20 0 10 20 30 40 50 60 70 80 90 Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10 Jul-10 Total spare parts Cost L.E./ ton Actual cost L.E./1000 pack Standard cost L.E./1000 pack • The total standard spare parts cost/ 1000 pack = 20 L.E And still waiting confirmation from TP Co.
  • 15. 6 – Cost Control Projects D - CIP 1.9 1.6 1.3 1.3 1.2 1.2 1.1 1.5 1.3 3.2 2.9 2.2 2.3 2.3 2.2 2.0 2.7 2.4 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 Dec-09 Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10 Jul-10 YTD Kg Acid / ton product Kg Soda / ton product
  • 16. 6 – E – Wastage in L.E. 2.36% 1.60% 1.20% 2.40% 0.00% 0.50% 1.00% 1.50% 2.00% 2.50% 3.00% TP section Glass section Yogurt section Total Wastage Value % Wastage Value %
  • 17. 7 – New Project ( Cost & Time frame )
  • 18. 8 – QC Report – Returns • Reason for Sales return qty in Cartons: Product Sales return Qty Due to bad handling in carton Sales return Qty Due to Expire date Manufacturing drained &reprocessed in carton Total Milk 1 L 1 158 172 45 1 375 Flavoured Milk 200 ml 529 204 1 734 Milk Joy 637 174 0 811 Juice 1 L 673 21 40 698 Juice 200 ml 61 4 0 65 Glass 1 L 120 9 0 129 Glass 250 ml 858 38 4 900 Yoghurt ( cups ) 846 2 482 0 3328 Yoghurt ( Gallons – 4 kg ) 277 4 608 0 4 885 Samples and Lab Analysis 1 – All Production was released after QC approval this month 2 – No market complain about taste ( approved recipes ) 3 – 26 costumer complaints during this month , most of them as a result of Recap of one liter 4 – No Spoil ( un-sterility ) during this month
  • 19. 9 – Pending* achieving works Pending Works : 1 – The main issue for Environment project, supply Government water and sewage pipe line ( waiting for fund ) 2 – Repairing Electric generators, synchronization unit and interconnection with new electric room ( waiting for fund ) 3 – Complete overhauling for main pasteurize plant – Waiting TP reply 4 – Install the new RO plant – 15 / 5 / 2010 5 – Install the drink unit received from Al-Misrieen Waiting TP reply 6 – Upgrade of Old flex (UHT) – post bond till arrange between Enjoy and TP 7 – Water collection for all processing equipment – waiting quotations 8 – Fire alarm system ( waiting for fund ) 11 – milk tanker local quotations were received and waiting overseas quotations Achieving Works : 1 – TWF filling m/c start production this month 2 – Boilers overhauling were completed 3 – Spoiling product room was completed with new well and m/c was transferred 4 – More than 3000 wooden pallets were produced from scrape wood 5 – New extension project, waiting final offer after complete technical discussion 6 – Al-Zomer store was completed and ready to sore finish product