LOGISTICS PANEL ASSESSMENT b. Unilever RFM Ice Cream Inc.

– Selecta Ice cream

sachet
OVERVIEW c. Lamoiyan – personal & household care products
1. Production Planning (Hapee, Dazz sachet)
- Orders d. Derm Pharma – personal care (Gluta White & Firm,
- Production Schedule Derm A, Derm Plus)
- Job Order e. Pet One Inc – dog food (SM Bonus dog food)
- Machine Schedule f. Invivo NSA Phils – chicken feeds (Warhawk)
g. Refinette Cosmetic Industry – cosmetic products
2. Raw Material Planning (Myra E)
- Computation h. ACS Manufacturing Corp – household (Pride
- Purchasing Detergent)
i. IMSPI – powdered drinks (Coffee Joe)
3. Report Making j. INAVET Nutrition Technologies Inc – animal
- Waste Monitoring supplements (Swine Lean Pak, Sow Performance Pak)
- Speed
- Machine Efficiency PRODUCTION SCHEDULE
- Machine Utilization 1. Preparation and Computation of Production Schedule
- Receive order and 3 months’ projection from sister
4. Costing companies
- Alternative raw materials - For sister companies such as Rebisco, First Baker
Corporation, Best Baker Food Inc, Multirich Food Corporation,
CONVERTING Suncrest Foods Inc, and SPI Corporation computation of
quantity to be produced are as follows
PRODUCTION PLANNING 4 weeks’ order + 2 weeks’ advance production
1. Receive Order from Client - For JBC and Pinnacle, computation of quantity to produced
2. Production Schedule is based on order only
3. Job Order – based on approved Prod Sched - For external clients, Production Schedule is based on order
4. Distribute Job Order only
- Ink Matching, Printing, Lamination, Slitting - Get Daily Finished Goods Stock Position from Warehouse as
- Warehouse of 6am, 27th day of the month
- QC - Get Daily Stocks In Process Monitoring from Converting as
of, 27th day of the month
RECEIVE ORDER FROM CLIENT - Secure Printing Balance as of 6am, 27th day of the month
1. INTERNAL CLIENTS from Production Planner
 Sister companies – monthly order - Get Delivery Balance from Sales Coordinator as of 6am, 27th
Orders and 3 months’ projection thru fax / email day of the month
 JBC and Pinnacle – Purchase Order ang gamit - Compute final quantity to be produced
- Submit PS to Senior Analyst & Asst. Logistics Head for
Internal Clients checking and/or revisions
a. Rebisco – biscuits - Submit PS to Logistics Head for approval
b. Suncrest Foods, Inc. – snack and cake products
(doowee, chocotops, Mrs. Goodman, funky) JOB ORDER (Existing)
c. JBC Foods Corp – nuts and seed snacks (happy, 1. Get Prod Sched from Prod planner
dingdong. Dragonseed) 2. Check material specs from Updated Product Information
d. Multirich Food Corp – cream paste and wafer Sheet
products (krimstix) 3. If existing product, mark exact repeat if without change,
e. SPI – candies and REPEAT WITH CHANGE if there are changes made.
f. SFI Multimix – dairy products (creamline)
Note: If REPEAT WITH CHANGE get Product Change Notice to
2. EXTERNAL CLIENTS serve as a basis of changes and indicate changes on JO
- receive Purchase Order from BDO of Sales Department
- PO must be approved by Managing Director 4. Input total qty to produce based on CVT Prod Sched (kg)
- no particular time for order

External Clients
a. Cosmetique Asia – cosmetic products (Silka Papaya,
soap and lotion sachets)
FORMULAS:
Total gsm = (printing substrate x density) + ink gsm + adh gsm
+ (laminant film x density)
Weight per roll = (total gsm/1000) x (roll width/1000) x length
per roll
Number of rolls = total qty to produce / weight per roll
Meters to produce = Number of rolls x (length per
roll/number of outs across) / waste allowance
Note: Waste Allowance
500kg – 1000kg = 15% (for double process in Lamination only)
Below 2000kg = 10%
2000kg and above order = 7%
Ink gsm
- Based on previous JO or on updated 3 months’
documentation of Daily Ink Dry Weight Monitoring from QC
Ink Requirement computation per color
- Get Ink and Solvent Consumption Report of Ink Matching to
determine the previous meters produced and ink consumed
of each product
Ink Requirement = (Previous Ink Consumption / Previous
meters produced) x qty to produce in meters
Slitting guide to guide = repeat across x number of outs +
2mm
Constants
Printing substrate: (printing substrate thickness/1000) x
density x (film width/1000)
Laminant film: (laminant film thickness/1000) x density x (film
width/1000)
PRINT: ((printing substrate thickness x density x print
gsm)/1000) x (film width/1000)
LAM: ((printing substrate thickness x density + print gsm +
adh gsm + laminant film thickness x density)/1000) x
(((printing substrate film width + laminant film
width)/2)/1000)
SLIT: ((printing substrate thickness x density + print gsm + adh
gsm + laminant film thickness x density)/1000) x (repeat
across/1000)
TRIM: (((printing substrate film width + laminant film
width)/2) – (repeat across x number of outs across)) /
(printing film width + laminant film width)/2 x 100
5. Submit JO to Senior Analyst & Asst. Log Head for checking
- If repeat with change, check JO details pertaining to
changes made. Verify details based on the attached
documents (RS, Product w/ change notice, QC
Memo, and other documents)
- If exact repeat, no need to check all JO details
- Verify product name and quantity based on
production schedule
- Indicate delivery date based on required delivery
dates on PO
- Check qty of films to be used based on WHS Raw
Material Stock Position and Slow Non Moving
Report. If no available film, recommend alternative
film to be used.
- Return to Jr. Analyst if there are revisions, if no
revision forward to Log Head for approval
6. Distribute 8 copies (QA, Production, IMT, PRT, LAM, 2 SLT,
WHS)
JOB ORDER (NEW PRODUCT)
1. Receive copy of Technical Specifications from R&D
2. Receive cylinder requisition slip and New Product Notice
from Technical Sales Engineer
3. Send winding direction from customer to determine their
required delivery figure and indicate it in JO
4. Get Production Schedule from Production Planner
5. Indicate the JO number and coordinate with Ink Matching
Supervisor for the color guide number
6. Include the name of the product and the customer’s name.
For Outside Job, PO# is included
7. Since it is a new product, MARK NEW JOB
8. Compute and include the following
- Input total quantity to produce based on CVT Production
Schedule.
- Get cylinder size, repeat around, across and number of outs
across from cylinder RS
- Input the following based on Tech Specs: Printing substrate
(thickness & width), sealant, ink gsm, adhesive gsm and
length per roll
9. Specify the type of Printing, reverse or surface, type of ink
10. Adhesive
11.Color sequence, solvent ratio
JOB ORDER (REPLACEMENT RUN)
1. Receive replacement memo from converting
2. Make a new copy from previous JO that needs to be
replaced
3. Type the word replaced under JO #
MATERIAL PLANNING
Raw Material Computation
1. Get quantity to produce from Production Schedule
2. Get Daily Raw Material Stock Position from Warehouse as
of 6am, 27th day of the month
3. Get Raw Material Daily Running Balance and Printed Stocks
(for sealant films only) from production as of 6am, 27th day of
the month
4. Secure Printing Balance from Production Planner as of
6am, 27th day of the month (for sealant films only)
5. Secure PO Balance from Raw Material Coordinator as of
6am, 27th day of the month
6. Compute for the final quantity to be ordered
- Imported & Local Raw Materials: 1-week buffer
7. Schedule expected date of departure from supplier
considering the following
- Lead time
- Sailing
- Releasing
- Arrival at Omni must be 1 week before production
8. Prepare the following reports
- Film price update (OPP, HSOPP, Matte OPP, Coex OPP,
VMCPP, Plain CPP, Nylon, CorPET, ChemPET & VMPET)
- Raw Material Requirements (for PE films for tolling)
- Raw Material Computation for adhesive
9. Submit to Asst. Logistics Head & Logistics Head for checking
and/or revision
10. Submit Raw Material Computation to Managing Director
for approval (for imported raw materials only)
RAW MATERIAL ORDERING
Objective: To provide proper direction in purchasing raw
materials having the right specifications and enough quantity
for guaranteed and continuous production
1. Receive approved RS from Jr. Analyst
2. Check RS if with complete details
- Name of item
- Quantity
- Application
3. Ask for duration of stocks and target delivery date from Jr.
Analyst
4. Make a call to existing suppliers (minimum of 3 suppliers)
or raw material to ask for the latest price.
5. Choose among the suppliers while considering the
following:
- Lowest price
- Terms of payment
- Availability of stocks
- Allocation
6. Prepare PO
7. Submit to Logistics Head for checking and to Managing
Director for approval with the following attachments:
- Previous PO (if with price changes, prepare half
sheet with recommendation)
8. If disapproved, revise PO
9. If approved, send PO to supplier thru fax or email
10. Call the supplier and confirm receipt of PO
11. Inform supplier on target delivery date
12. Log PO details on PO Monitoring Sheet
13. Forward original and pink copies of PO to accounting clerk
14. Ask accounting clerk to sign on the yellow copy as a proof
of acceptance
15. File the yellow copy for traceability purposes
16. Confirm delivery from supplier two days before expected
date of arrival at Omni
Note: Lead time on raw materials deliveries is 1 week before
production run
MACHINE SCHEDULING
1. Use the following reports as basis for machine scheduling
- Production Schedule
- Orders
- Raw Material Inventory
2. Receive Raw Material Stocks Inventory from WHS to
determine if there is enough quantity of raw materials for
every JO. If there are shortages, check with client the
duration of their stocks (finished goods and raw materials). If
possible to extend delivery schedule, ask for adjustment,
otherwise below are possible options:
- Look for the possible size to be used preferably with
the least trimmings next to the original size
- If 1st step still not applicable delete number of out/s
across depending on available film with no or least
trimmings
- Get the approval of Managing Director for material
loan to other converters
3. Consider the quantity of the products to be produce in
choosing machine
- Medium run use IKD and Daejin
- Long run use Long New Machines
4. If possible, schedule the same sizes to minimize set up time
due to IRR change
5. Number of hours in printing
Formula:
((Quantity to produce in meters) / (Actual Speed of Printing
Machine x 60 minutes)) / 24 hours
- Actual Average speed in DJ and IKD = 150 mpm
- Actual Average speed in LN = 170mpm
6. Start-up time
Formula for start up time with change IRR on set up
= Ending time of last job + (60 minutes set up time/24 hours)
Formula for start up time without change IRR on set up
= Ending time of last job + (35 minutes set up time / 24 hours)
7. Determine the ending time of JO in Printing
Formula: Start up time + number of hours to be consumed in
printing
8. Indicate delivery date
9. Submit machine schedule to Logistics Head for approval
10. Distribute the approved machine schedule to printing, Ink
Matching, QA, Ink Making and Manufacturing Head
Note:
Sensitive products, krimstix – bawal sa bostik, morfree ang
gamit
REPORT MAKING
Waste Report – profit loss
Printing Waste 3%
Production / Splicing 1.8
Ink 0.3 7. Submit Production Schedule of Ink Making to Senior
Film 0.15 Analyst and Asst. Logistics Head for checking
Cylinder 0.2 8. Submit Production Schedule of Ink Making to Logistics
Machine Trouble 0.2 Head for approval
Utilities Trouble 0.10
Slitting 0.25 B. Preparation of Job Order
1. Prepare JO based on approved PSIM
Lamination Waste 1.2% single process, 2.5% double process 2. Submit JO to Senior Analyst and Asst. Logistics Head for
Slitting Waste 0.03% checking
3. Submit JO to Logistics Head for approval
Overall
Short Run 15% (less than or equal to 60000) C. Distribution of Job Order
Medium Run 10% (60001 – 190000) - Give copy of Job Order to Ink Making Department
Long Run 7% (190001 and above)
PRODUCTION SCHEDULE
Pag less than 1% pwede na iclose ung job, isama na sa Objective: To provide proper directions in generating
consolidated waste report accurate production schedule for Ink Making and to meet the
required quantity of inks to produce
Machine Efficiency
Standard Efficiency printing m/c 80% 1. Receive Production Schedule
Lamination 2. Receive the following:
SF 50%, Ext 80%, SB 75%, PP 90% a. Client’s Order – from outside clients only
(Rotopack, Keiser, Primeflex, JAC, Markenburg, etc.
Speed = total output / production time b. Ink Making Stock Inventory – from IMK
Printing: DJ 150, LN 170 Department as of 6am, 27th of the month
Lamination: c. Daily Pure Ink Monitoring – from Ink Matching
VMCPP 240, CPP 300 (SF) section as of 6am, 27th of the month
VMCPP 150, CPP 120 (SB) d. Ink Daily Stock Position – from WHS as of 6am,
Ext 110 27th of the month
e. Printing Balance – from Production Planner as of
Utilization 80% 6am, 27th of the month
- Output f. Stock Summary – from Jr. Analyst of Converting
- Efficiency and speed 3. Compute Omni Stocks
Formula: Omni Inventory = IMK stocks + IMT stocks + WHS
Orders mataas, taas utilization stocks
Eff and speed mababa, taas utilization 4. Compute Production Balance (as of 6am, 27th of the month)
Standard Utilization Formula:
Actual Utilization Production Balance = Last month’s JO + Last last month’s
Production Balance – (Last last month’s output from 27 th day
to last month’s output until 26th day)
INK MAKING Example:
November Prod’n Bal = Nov JO + Oct Prod’n Bal – (Oct output
PRODUCTION PLANNING from 27th to Nov output until 26th day)
5. Get delivery balance from Sales Coordinator (as of 6am,
A. Preparation and Computation of Production Schedule 27th of the month)
1. Receive Production Schedule of Converting and Printing 6. Compute Present Month’s Ink Requirement
Balance as of 6am, 27th day of the month a. Input printing balance
2. Receive orders from outside clients (Rotopack, Keiser, b. Input quantity to be produced (based on Converting
Primeflex, JAC, Markenburg, etc.) Production Schedule)
3. Get the following as of 6am, 27th of the month c. Converting Requirement in kilograms = Printing
- Ink Inventory from Ink Making Department balance + Quantity to be produced
- Daily Ink Stock Position from Warehouse Number of slit rolls = Converting requirement in kilos /
Department Weight per slit roll
- Daily Pure Ink Monitoring from Ink Matching Section d. Converting Requirement in meters
4. Compute for Production Balance (as of 6am, 27 th of the Requirement (in m) = (Computed no of slit rolls x length per
month) roll) / (No of outs across x (100% - Waste Allowance))
5. Compute for final quantity to produce Note: Waste allowance (for Converting) are as follows
6. Prepare separate Production Schedule of Ink Making for 500 kg – 1000 kg = 15% (for double process in Lamination
Reverse and Surface Ink only)
Below 2000 kg = 10%
2000 kg and above = 7%
e. Basic Color previous ink consumption (per product per
meter) = (Ink formulation x Ink Consumption) / Quantity run
in meters
Note: Data is based from Ink and Solvent Consumption from
Ink Matching Section
f. Required Quantity of Basic Color in kilograms = Basic color
previous ink consumption per meter x Converting
requirement in meters
g. Apply to all basic colors
h. Sum all the values per color to get the requirement for the
month
7. Compute Mid Next Month’s Requirement
Formula:
Mid Next Month’s Req’t = Projection (based on Stock
Summary) / 2
8. Compute 1 week buffer
One week buffer = Mid Next Month’s Requirement / 2
9. Compute Quantity to produce of ink per color
a. Reverse inks
Quantity to produce = Omni Inventory + Production Balance –
Delivery Balance (outside client) – Present Month’s Ink
requirement (Converting Reverse Products) – 2 weeks
advance req’t – 1 week buffer
b. Surface inks quantity to produce is as per requirement only
(outside clients) since no Surface Products already.
10. Submit to Sr. Analyst & Asst. Logistics Head for checking
and to Logistics Head for approval
JOB ORDER (INK MAKING)
Objective: To provide proper directions in making monthly
job order for Ink Making Department to be able to give the
right type of raw material, formulation, type of ink and
quantity of ink to be produced.
1. Input the following
- Job Order Making
- Date of Job Order
- Product Name
- Input quantity to produce per color
2.Arrange and input raw materials according to types (resins,
additives, pigments, solvent)
3. Compute the quantity of raw materials to be used per color
Formula: Quantity per color x Raw Material Formulation
Note: Update formulation based on latest approved
formulation provided by Ink Making Department
4. Show the total quantity required of raw materials per
product
5. Print and sign JO
6. Submit JO to Senior Analyst and Asst. Logistics Head for
checking
7. Submit JO to Logistics Head for approval
8. Once approved JO, give 2 copies to Ink Making Production
Head
MATERIAL PLANNING (INK MAKING)
A. Raw Material Computation
1. Get the quantity to be produced and production balance
from Production Schedule of Ink Making
2. Get the following as of 6am, 27th day of the month
- Ink Making Raw Material Inventory from Ink Making
Department
- Daily Stock Position of Raw Material of Ink from
Warehouse Department
- Daily Pure Ink Monitoring from Ink Matching Section
(for PE bags inventory)
- PO balances from Raw Material Coordinator
3. Compute final quantity to be requested
4. Schedule ETA of raw materials at Omni
- Imported & Local Raw Materials w/ 1 week buffer
5. Submit Raw Material Computation to Sr. Analyst & Asst.
Logistics Head for checking
6. Submit RMC to Logistics Head for approval
7. Prepare Requisition Slip
8. Submit Requisition Slip to Sr. Analyst & Asst. Logistics Head
for checking
9. Submit RS to Logistics Head for approval
10. Give copy of RS & schedule of ETA at Omni of RM to RM
Coordinator for PO making
REPORT MAKING
1. Daily Production Summary Report
- machine, product name, material description, total
input, total output, solvent loss, % waste
2. Machine Efficiency
= (man hours – downtime) / manhour
Mixer = 80%
Grinder = 85%
Machine trouble = 5% max per month (report to Sir Alex)
3. Stock Summary (Report to Sir Alex)
Stock (End October) + Produced (Start – End November WHS,
IMK) + Reprocessed (Start – End Nov) – Delivery (Start – End
Nov) = Available (end Nov)
4. Waste Monitoring (Report to Sir Alex)
Input = Output + Waste
OPP Lam Inks – for outside (benta)
Omni ginagamit na ink
Flexilam Inks
OPP Lam Ink
Roto CP
CDI Lamiall
- 1 month projection
- Local
- 1 month requirement
Expected Ink Requirement
- Based 3 previous job (average)
Ink Requirement = Average previous job (3job/run) x quantity
present order
Actual = last run x present order
 - PE Bags
Machine Utilization -
Standard vs projection 10% Formula:
Standard vs actual 5% Total Requirement per month = (Quantity to produce in pcs x
Standard weight per pc x Mixing Ratio) + 1% allowance

MOLDING Final quantity to be requested = Total requirement for

present month + Total requirement for next month – WHS
PRODUCTION SCHEDULE stock – Production stock – PO balance

JOB ORDER (MOLDING)
1. Input the following
- JO Number
- Date of Job Order
- Product Name (Arrange items per product’s part)
- Quantity to produce in pcs (from Production
Schedule)
- Standard weight per piece in grams
- Type of raw materials to be used per product (PVC,
PET, PP resin, masterbatch)
- Mixing ratio of raw materials (virgin resin, recycled
resin, masterbatch)
2. Compute the required quantity of raw materials to be used
Formula:
3. Sign the printed JO
4. Submit Asst. Logistics Head and Logistics Head for approval
5. Give a copy to Molding Department Production Head
RAW MATERIAL COMPUTATION (MOLDING)
Objective: To provide proper directions in computation of
Moulding raw material and to ensure enough stocks raw
materials to be used in production
Note: Refer to Molding Product Information dated December
19, 2013 for specification, mixing ratio and packing
6. Duration
For excess:
Number of days = (Excess / Next month’s projected
requirement) x 30 days
For additional:
Number of days = (Additional / Next month’s projected
requirement) x 30 days
Duration date = Number of days + Cut off
Expected Target Arrival (Omni Plant) = Duration date – 7 days
7. Submit RMC to Senior Analyst and Asst. Logistics Head for
checking and to Logistics Head for approval
8. Submit RS to Senior Analyst & Asst. Logistics Head for
approval

1. Input quantity to produce

- Quantity to produce in Manila (Based on Production
Schedule of Manila)
- Quantity to produce in Bukidnon (Based on Prod
Sched of Bukidnon)
- Production Balance of Bukidnon and Manila
2. Receive the following
a. Plastic Moulding Daily Stock Position of Raw Materials
- From WHS as of 6am, 27th day of the month
b. Daily Raw Material Status
- From Molding as of 6am, 27th of the month
c. PO Balance (Incoming Shipment)
- From Raw Material Coordinator as of 6am, 27th
d. Section Head Daily Report (for Bukidnon only)
- From Molding, 6am, 27th
e. Delivery / Stock Summary
- From Jr. production Analyst (Molding)
3. Input received data
4. Computation must be good for 2 months
a. Present month – based on Production schedule
b. Next month – based on Projection (from Delivery /
Stock Summary)
5. Compute final quantity to be requested (additional / excess
) for the following raw materials:
- Resin
- Masterbatch