Ed Koch
Head of Manufacturing Development
Contents
SABMiller some context Operational Excellence at SABMiller The SABMiller Manufacturing Way Results Summary
200+ brands owned Presence in 75 countries, across six continents 140+ breweries, 20+ bottling plants, 10+ maltings Almost 70 000 employees 213 million hectolitres of lager sold US$26 350 million group revenue to Mar 10 * US$4 381 million EBITA to Mar 10 *
* Not Audited
Where We Operate
(hl000)
261,447
2%
Latin America Europe North America Africa Asia South Africa Beverages
12%
14%
19%
International Brands
Grolsch Premium Lager Miller Genuine Draft Peroni Nastro Azzurro Pilsner Urquell
SABMiller owns over 200 regional beer brands, including: 2M (Mozambique) Atlas (Panama) Carling Black Label (South Africa) Castle Lite (South Africa) Club Colombia (Colombia) Cristal (Peru) Dreher (Hungary) Gambrinus (Czech Republic) Hansa Marzen Gold (South Africa) Haywards (India) Kilimanjaro (Tanzania) Nile Special (Uganda
Pilsener (Ecuador) Pilsener (El Salvador and Honduras) ari (Slovakia) St Louis (Botswana) Timisoreana (Romania) Lech (Poland) Velkopopovick Kozel (Czech Republic) Zolotaya Bochka (Russia)
First acquisitions in Europe 1988 Compania Cercercera de Canarias in Canary Islands 1993 Dreher in Hungary 1895 Foundation of South African Breweries and launch of Castle Lager 1897 Listing on Johannesburg stock exchange 1898 Listing on the London stock exchange Regional and product expansion 1978-82 Botswana, Lesotho and Swaziland 2003 Acquisition of Birra Peroni, Italy 2008 Acquisition of Grolsch, The Netherlands 2008 MillerCoors JV created, USA
1895
1910 Expansion into Zimbabwe (formerly Rhodesia) Global growth begins 1993 Uganda 1994 Angola, Mozambique, Tanzania, Zambia, China 1995 Poland 1996 Romania 1997 Ghana, Slovakia 1998 Russia 1999 Czech Republic 2000 India 2001 El Salvador, Honduras, strategic alliance with Castel Group in Africa 2002 Creation of SABMiller following purchase of Miller Brewing Company 2005 Merger with Grupo Empresarial Bavaria
2010
Acquisition in South Africa 1956 Ohlssons, Chandlers Union Breweries 1975-79 Old Dutch, Whitbreads, Swaziland breweries, beer interests of the Rembrandt Group attaining 99% market share
SABMiller has a clear strategic focus, at the centre of which are our four strategic priorities: Creating a balanced and attractive global spread of businesses Developing strong, relevant brand portfolios in the local market Constantly raising the performance of local businesses Leveraging our global scale
Operational Excellence
1. Building pride in the technical fundamentals of our brands. 3. Developing a reputation for product and packaging innovation.
2. Enhancing our reputation for operational excellence. 4. Enhancing the sustainability of our supply chain.
Increasing Performance
1. 2. 3.
Quality and Production Upgrade Strategy 1988 1992 1996 2000 2004 2008
Principles Principles
Principles Principlesand andphilosophy philosophythat thatensures ensuresan an integrated approach for Operational Excellence integrated approach for Operational Excellencein in the context of business strategy. Long term the context of business strategy. Long term thinking thinkingwith withaabusiness businesscase casefor forchange. change. Build Buildan anorganisation organisationto toimplement implementand and sustain operational excellence including sustain operational excellence including structures, structures,roles rolesand andjobs. jobs. Enable Enableperformance performanceand andcapability capability transformation transformationthrough throughchange changeleadership leadership and a deliberate approach to learning. and a deliberate approach to learning. Enable Enablecontinuous continuousimprovement improvementthrough through collaboration and development of collaboration and development ofnew new competencies. competencies. Processes Processesto toEnhance EnhancePerformance Performance including teamwork, standard including teamwork, standardwork, work, waste elimination and other work waste elimination and other work practices. practices.
Country Lead
Country Lead
Country Lead
Brewery Consultant
Country Team
Brewery Consultant
Brewery Consultant
SABMillers partnership with CCI extends more than 20 years. Currently CCI actively consults in over 50 of SABMiller operations. It is fair to say that CCI has supported SABMillers global expansion by providing thought leadership and consulting support into the operational excellence approach. Operational excellence has been fundamental in driving SABMillers growth.
Unsustainable Results
WCM Excellence
Therefore SABMiller measures operational excellence in terms of both the what we achieve (Results) as well as the how we go about achieving our results (Work Practices and Processes)
The Global Evaluation of Manufacturing is a SABMiller customised version of the TRACC Assessment tool. The content was customised by SABMiller to include our own learning and knowledge. The tool was developed and is supported by CCI.
Principles Principles
Key elements
The following slides illustrate some of the key elements of our approach to operational excellence.
Organisational Model
Policy Deployment & Performance Management
Definition of Performance Management Core to our culture and our ways of working, performance management is how we manage the performance of teams and individuals against goals through personal accountability, which drive execution of the business strategy in a way that shapes a high-performance, high-engagement culture and ensures sustainable business performance.
Performance data feeds into key decisions on compensation, Individual development and career management
Key input
Process steps
Key output
Shift Shift Team Team Leader Leader Operator Operator Skill Skill 1 1
Level Level 1 1
Operator Operator Skill Skill 2 2 Mech. Mech. Crafts Crafts Electrician Electrician
Daily Level 3 meeting of department and area managers covering safety, production to plan, quality and cost
Common Measurement
Lessons Learnt
Operational Excellence is entirely dependent upon a resolute process of continuous improvement. Performance and practice are measured against internal and Standards external benchmarks. Organisational Learning and Collaboration are important aspects of the improvement process. Individual competence and development is promoted.
Better Practice
Competence and Capability Benchmarking The Manufacturing Global Key Performance Indicators (KPI) Process enables benchmarking. Principles Focus: the Global KPIs are limited to 15 measures. Balance: measures are spread across the key manufacturing drivers. Common measurement: a defined set of procedures and rules. Benchmarking Focus: drives continuous improvement in a sustainable way
100
120
20
40
60
80
0 TOP 25% East Coast Quito Medellin Boyac Cusco Malabar Arequipa Bucaramanga Ind La Constancia Tocancipa Bogot Bialystok Tychy Motupe San Pedro Sula Kaluga Plzen Poznan Velke Popovice Central Distillers 98.37 96.62 94.85 94.66 94.61 94.25 94.20 93.66 93.49 93.20 92.67 92.43 92.16 91.31 91.18 91.10 91.04 90.97 90.82 90.58
Machine Efficiency - Best and Worst Quartile Ranked - Mar F10 (YTD)
Std Dev = 10.13 76.42 76.00 75.72 74.75 73.71 73.42 72.88 71.16 70.97 69.00 67.32 67.23 65.84 65.07 62.75 61.80 60.03 59.81 58.70 58.05
Bialystok Poznan Fort Worth Tychy Guayaquil Beer Trenton Ind La Constancia Ibhayi Kaluga Boyac Eden Nosovice Newlands Shenandoah Prospecton Albany Velke Popovice Grolsch Polokwane Bucaramanga
Quality (Brewery Hygiene, Consumer Predictive Index, Flavour Stability Index, Packed Product Quality, Total Packaged Oxygen)
Albany Rosslyn Bari Vladivostok Dar es Salaam Shenandoah Lusaka Beer Charminar Maputo Lesotho Beer Golden Grolsch Accra Sarmat Kgalagadi Beer Lubango Swaziland Beer Beira Haryana Ulyanovsk
hl/hl 10 12 14 16 0 2 4 3.10 3.24 3.42 3.50 3.53 3.64 3.65 3.69 3.77 3.78 3.84 3.84 3.87 3.95 3.95 3.96 3.99 4.07 4.07 4.10 6 8
TOP 25%
Water Ratio - Best and Worst Quartile Ranked - Mar F10 (YTD)
Productivity (Unadjusted Factory Efficiency, Machine Efficiency) Cost (Total Cost of Manufacturing, Cost of Maintenance, Macro Extract Loss, Container Loss)
5.70 5.84 5.91 6.08 6.23 6.72 6.87 6.92 6.95 7.19 7.33 7.41 7.51 7.58 7.64 7.77 8.01 8.29 9.50 13.62
Cluj Vladivostok Lubango Dar es Salaam Nile Buzau Mwanza Sarmat Lesotho Beer Sica Pondicherry Swaziland Beer Arusha Central Distillers Beira Accra Kgalagadi Beer East Coast Maputo Lusaka Beer Vietnam Beer
Description SAFETY / PEOPLE DART Rate Salaried - Budget Salaried - Actual Salaried - Budget (Temps) Salaried - Actual (Temps) Hourly - Total Hourly Temps Hourly - Sick/Personal Hourly LOA Hourly FMLA's QUALITY TPO - BOTTLES TPO - CANS ESR - FV (T150's) CQI: Taste CQI: Clarity CQI: Foam Flavor Stability Index PPQA - Bottles PPQA - Cans SERVICE Production Volume - Plan Production Volume - Actual Weekly Order Fulfillment FE OEE ME
Unit of Measure
Corporate Targets
Milwaukee
Eden
Albany
Trenton
Ft. Worth
Irwindale
Golden
Shenandoah
# # # # # # # % % %
# # # % % % % 6 Sigma 6 Sigma
(LM Only) 83 123 25,826 56% 89% 36% 58% 4.9% 4.7%
Shopfloor
Management
10
20
30
40
50
60
70
0 Packaging Stoppages Bottle Breakage / December Carton / Trays Losses Malt Transfer Losses Beer Losses in Packaging Beer Losses in Brewing Material Usages Material Usages Material Usages Usage of Laboratory Material Losses and Usages
Loss Analysis: the difference between Focused Improvement and Continuous Improvement Example below is from Kaluga Brewery, Russia
Time Losses
December
Ruble/Hl
Empty Bottle Breakage Flt's Gas Usage Quality Losses Quality Losses Quality Losses Gas Usage (Utilities) Water Usage (Utilities) Energy Usage Maintenance Costs Waste Water Utilisation Electricity Usage Brewing Maintenance Packaging Maintenance Warehouse Maintenance Utilities Maintenance
YTD
Month
best result
Work Practices
Asset Management and Autonomous Maintenance
Autonomous Maintenance forms part of the Asset Management programme to ensure conditions for equipment operation and care are standardised and effective
Run to fail
Emergency Maintenance
Scheduled Maintenance
(Time Based)
Corrective Maintenance
Predictive Maintenance
(CBM)
Autonomous Maintenance
Results
WaterHL/HL
12.00 10.00 8.00 6.00 4.05 4.00 2.00 0.00 F02 F03 F04 F05 F06 F07 F08 F09 11.15
ThermalEnergyMJ/HL
180.00 160.00 140.00 120.00 100.00 80.00 60.00 40.00 20.00 0.00 F02 F03 F04 F05 F06 F07 F08 F09 93.41 164.24
128 97 72 72
FY06
FY07
FY08
FY09
80
70
60
50
40
Annual Total LH
F05
90,000 80,000 70,000 60,000
75% 76% 77% 78% 79% 80% 81% 82% 83% 84% 85% Annual Avg ME
126%
90%
Machine Efficiency
80%
109%
107%
110%
100%
70%
99%
100%
100%
60%
90%
80%
Machine Efficiency
117%
120%
35
31 27 21 17 13 7 8 6 1 18 22 19 17
Number of Operations
30 25 20 15 10 5 -
< 1.5
1.5 - 2.0
2.0 - 2.5
2.5 - 3.0
> 3.0
GEM Maturity 1 0 10 20 30 40 50 60 70 80 Africa Asia Europe Latin America MillerCoors South Africa 1.5 2 2.5 3 3.5 4
Summary
Senior leadership belief in, and engagement with the process. A team based organisational design (structure, roles, practices) is most effective for delivering continuous improvement. Policy deployment through a structured performance management process. Optimise the system or process, not the functional area. Operational Excellence is entirely dependent upon a resolute process of continuous improvement.
Benchmarking performance and practice internally and externally. Strong partnership with thought leaders and outside experts are important to build internal capability and to maintain an external perspective. Organisational learning and collaboration are important aspects to the improvement process. Individual competence and development is crucial. We are still on the journey we are still learning.
In the end
Organization doesn't really accomplish anything. Plans don't accomplish anything, either. Theories of management don't much matter. Endeavors succeed or fail because of the people involved. Only by attracting the best people will you accomplish great deeds.
General Colin Powell
Chairman (Retired), Joint Chiefs of Staff Army of the United States of America