Scaling up Higher Quality Coffee in Esat Africa - Experience from Ethiopia
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.
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 %
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