lanner client britvic discuss their leeds factory & warehouse simulation
TRANSCRIPT
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Neil Brinkman, David RiceBritvic Soft DrinksLeeds factory & warehouse simulation
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Agenda
• Introductions• Introduction to Britvic• Simulation overview• Project overview• Findings\summary
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Making life’s everyday moments more enjoyable
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Leading branded soft drinks business
More than 30 brands
More than 30 brands
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Strategy
Being thebenchmark
integrated brandedsoft 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
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Leading branded soft drinks business
£1,321.9mGroup revenue
Source: Britvic Plc Annual report 2013
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Leading branded soft drinks business
3,300employees
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Leading branded soft drinks business
2,066.9mlitres per year
Source: Britvic Plc Annual report 2013
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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
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Owned brands in UK
Franchised brands in UK
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Where we operate - GB
Hemel Hempstead
Solihull
Factories
Offices
1850 employees
Lutterworth
DistributionNorwich8 lines PET
Beckton4 lines Plastic (PET)
Rugby6 lines Can,PET and Aseptic
Leeds3 lines Glass and Bag in box1 PET line
640 products
Where we operate
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The simulation challenge
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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.
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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
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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
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Leeds - Skyfall New loading bays
New warehouse
New staff & visitor parking
New trailer parking
New production Line
Existing production lines (3)
Gatehouse
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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
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Beginning to see the output from the modelling…
One way system out into the loading bayTraffic flows in to the warehouse
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Beginning to see the output from the modelling…
Warehouse starting to take shape Loading bays – nearly ready for use
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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
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Any questions?