Daily Review of Production

FORSAN FOODS FACTORIES

ISSUE 1

FORSAN BAKERY FACTORY

QF/PR/PL - 04

Date of production : 18.06.2013

Actual output/hr=Total Kg produced/Actual production (hrs)* Total time for production=Actual Production Hrs +Abnormal process related stoppage+Normal Stoppage(Excluding allowable normal stoppage) Abnormal machine related stoppage & Normal allowable stoppage time will not be included in the productive time OEE = MACHINE AVAILABILITY x PERFORMANCE x QUALITY Total Planned time for production = Total time under production - Normal allowable stoppage time Machine Availability = Actual production time / Total planned time for production Performance = Actual production per hr / Standard production per hr ( If out put comes more than standard we are considering the performance as 100%)
USAGE OF USAGE OF MIXING NIGHT TOATL USAGE OF MIXING FLOUR Production plan in (Pcs) SHIFT DAY Production plan in (Pcs) SHIFT NIGHT Actual Production in (Pcs) TOTAL Actual production (hrs) DAY Actual production (hrs) NIGHT Total time under production (Mins) Actual production (hrs) TOTAL Stoppage timeABNORMAL Machine related Stoppage timeABNORMAL process related Stoppage timeNORMAL allowable Reason for Quality % OEE % ABNORMAL stoppages Reason for NORMAL stoppage Remarks MIXING Weight KG

Production Line Name

Product Name

Standard Output / hr

MIXING DAY

Total planned Time (Hrs)

Total Stoppage time (Hrs.)

Qty Rejection (pcs)

Actual production /hr

Performance Efficiency %

Machine Availability %

FLOUR SHIFT FLOUR SHIFT

27.00

Burger Large - 5 " FRESH (Regular/Seed)

5800

300

195

495

5640

3833

9473

65

44

109

1.82

1.63

0.18

126.00

5214

90%

90%

99%

80%

947.3

Burger Medium - 4" FRESH (Regular/Seed)

6650

295

210

505

7560

5760

13320

77

54

131

2.18

2.00

0.18

192.00

6101

92%

92%

99%

83%

999

Dinner Roll - 3 & 3.5" FRESH (Regular/Seed)

5500

25

70

95

2160

3450

5610

24

38

62

1.03

1.02

0.01

12

5429

99%

99%

100%

97%

196.35

Hotdog FRESH (Regular/Seed)

3500

10

10

300

300

0.10

0.09

0.01

3000

86%

86%

99%

73%

18

FORTUNA

Burger Large - 5 " FROZEN

5600

0.00

0.00

0.00

Burger Medium - 4" FROZEN

6000

0.00

0.00

0.00

Dinner Roll - 3 & 3.5" FROZEN

6500

0.00

0.00

0.00

Hotdog MINIFROZEN

5500

0.00

0.00

0.00

Hotdog FROZEN

5500

0.00

0.00

0.00

SoupBread
FORTUNA MANUAL

2000

0.00

0.00

0.00

Bugutte

2200

25

20

45

312

276

588

17

0.28

0.27

0.02

2075

94%

94%

100%

89%

70.56

HONEY BREAD

4500

66

66

1590

1590

22

22

0.37

0.35

0.01

14

4336

96%

96%

99%

92%

127.2

JUMBO SAMOLI PLAIN

FORTUNA KAKI

2500

45

50

95

694

793

1487

18

18

36

0.60

0.59

0.01

2478

99%

99%

99%

98%

193.31

JUMBO SAMOLI SESAME

2500

80

25

105

1318

348

1666

33

42

0.70

0.67

0.03

12

2380

95%

95%

99%

90%

249.9

JUMBO SAMOLI-SESAME POTATO

2500

0.00

0.00

0.00

SAMOLI

600

0.00

0.00

0.00

Bugutte SAMOLI (FROZEN)BLIMBE

600

0.00

0.00

0.00

600

0.00

0.00

0.00

KAKI - MANUAL

TPC

750

50

50

576

576

47

47

0.78

0.77

0.02

735

98%

98%

100%

96%

80.64

DUO

150

0.00

0.00

0.00

VAPIANO

600

0.00

0.00

0.00

PANINI - ZATTAR - CIBBATA

700

25

25

406

406

40

40

0.67

0.58

0.09

609

87%

87%

100%

76%

44.66

SHETER DOUGH DIVIDER

PANINI 65 G

400

0.00

0.00

0.00

CIABATTA - SANDWICH

600

0.00

0.00

0.00

TOAST BREAD SMALL

MANUAL

100

25

25

64

64

40

40

0.67

0.64

0.03

96

96%

96%

100%

92%

54.4

TOAST BREAD LARGE

100

0.00

0.00

0.00

CROISSANT SHETER

CROISSANT

200

40

40

609

609

205

205

3.42

3.05

0.37

178

89%

89%

100%

79%

91.35

1556

35689

757

370

87%

TOTAL

3072.67

Note: This only for the formation of the Dough, after that the dough going into proofing room and complete all processing steps( Proofing, Baking, Cooling, Packing etc..)

List Of Normal Stoppages

For Mixing line / Fortuna we have mainly the following category for normal stoppage: Surrounding cleaning : 30 mins every 6 hrs (max).120 mins/day Cleaning of the mixer machine: @45 mins per shift90 mins/day Product changeover: 20 mins for Product changeover frm Dinner Roll to BM/BL or BM/BL to Dinner Roll

Flowpack machine: Wrapper change over : 4 mins/ wrapper change @ 6 rolls change per day..24 mins/day/machine Pack size changeover: 15 min for Burger Medium (BM pack size changeover.

List Of Normal Stoppages

For Mixing line / Fortuna we have mainly the following category for normal stoppage:

Surrounding cleaning : 30 mins every 6 hrs (max).120 mins/day

Cleaning of the mixer machine: @45 mins per shift90 mins/day

Product changeover: 20 mins for Product changeover frm Dinner Roll to BM/BL or BM/BL to Dinner Roll

Flowpack machine: Wrapper change over : 4 mins/ wrapper change @ 6 rolls change per day..24 mins/day/machine

Pack size changeover: 15 min for Burger Medium (BM pack size changeover.

Product Description )5 x 4 Kg(Forsan Dark Choco Compound )5 x 4 Kg(Forsan Milk Choco Compound )5 x 4 Kg(Forsan White Choco Compound ) 1 x 20 Kg(Forsana Chocolate Ice Cream Coating No of one year working days

2013 168 120 192 526

Total No of days Lagging /leading

Total Capacity

1000 tons with above products % distrubu

No of days required 56 40 295.3846154 175.3333333

566.7179487 280 -286.7179487

Old Machine-1 56 40

New Machine-2

295.384615 175
271 280 9 295.3846154 280 -15.38461538

ns with above products % distrubution