Manufacturing KPI Review by CEO-Aug Final 10

1
MANUFACTURING KPI REVIEW
AUGUST 2010
Contents
2
Strategic KPI’s Operational KPI’s People development Project KPI’s
Page Page Page Page

SKU Availability at  Divisional  Management of Waste Reduction 39
Agent level 3 Overheads 20 Knowledge Pool Raw Material cost
SB Cost per dozen 8  Outstanding  Turnover of Key reduction 39
Consumer Quality Internal Audit People Sale of Excess
Index 11 Issues 36  Training & Co2 39
Capacity Utilization  No MNC at development
(BH) 15 External Audits 35  PEAP Completion
Technical &  Hygiene Audit
Technological Score 38
Innovations 18
Strategic KPI – 1. SKU availability
3
KPI Efficiency Measurement Cost Measure

Page MTD YTD
Page MTD YTD Packaged volume 12 FG Inventory holding
SKU availability at cost (Also reflected by
FG Inventory the volume) Page MTD YTD
agents 4 (Agents+LBCPLC) 12
17
Forecasting accuracy 13

Inventory Cover days 13

14

15
16
Below TGT
Par with TGT
Above TGT
FG Inventory (days) as at 1st of
Strategic KPI – 1. SKU AVAILABILITY each month calculated based on the
1.1 SKU availability & inventory holdingnext month’s sales target
4
In v en to ry (d a y s)
6000%
5000% 5
7 4
4 1 4 4 5
4000% 6 5 7 6 1 3
0 3 6
2 6 4
5 4 13 14 4
3 15 12
3000% 17 17 15
15 16
16 17 18
2000%
29 28 25 27
1000% 18 19 20 22 21
15 16 15
0%
Sep '09 Oct '09 Nov '09 Dec '09 Jan '10 Feb '10 Mar '10 Apr '10 May '10 Jun '10 Jul '10 Aug '10
Ten days FG inventory (Agents + LBCL) taken
Strategic KPI – 1. SKU AVAILABILITY as the standard and calculated the (%) above or
below target. (+) % means volume above or
1.2 SKU Availability-FG Inventory below target as a % of 10 days requirement
5
SKU Availability Index – %Variance against standard of 10 days FG inventory (reporting

month)
Overall
500Cans
300Cans
Kegs
Pts
Qts
-50 0 50 100 150 200
(%)
Strategic KPI – 1. SKU AVAILABILITY Overall RD sales -2.37%
1.3 SKU Availability-Forecast Vs Sales
6
800,000.00
700,000.00
600,000.00
Volume doz.
500,000.00
400,000.00
300,000.00
200,000.00
100,000.00
0.00
Strategic KPI – 2. SB Raw Material Cost
7
KPI Efficiency measure Cost measure

Page MTD YTD
Page MTD YTD Malt Price 12 Page MTD YTD
SB Raw Material cost Rice Price 12
per dozen 9
Sugar Price 13
Usage Variance

Below TGT
Par with TGT
Above TGT
Strategic KPI – 2. SB Raw Material cost
2.1 Direct Raw Material Prices
8
Direct Raw Material Prices

4,540.00 120.00
4,040.00
100.00
3,540.00
3,040.00 80.00
2,540.00
Rs/kg
60.00
2,040.00
1,540.00 40.00
1,040.00
20.00
540.00
40.00 -
Strategic KPI – 2. SB Raw Material cost
2.2 SB Cost/hl for each SKU
9
Raw Material Cost/hl for SB SKUs
1, 2, 3, 4, 5, 6, 7, 8,
3
Average
30l ... Month
330ml...
500ml...
6P
Strategic KPI – 2. SB Raw & Packaging Material cost
2.3 Usage Variance
10
2,700.00 12
2,600.00 10
2,500.00 8
Tgt. 2425Rs/hl
2,400.00 6 Axis Title
2,300.00 4
2,200.00 2
2,100.00 0
Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug
11
Strategic KPI – 3. Consumer Quality Index
Page MTD YTD
Page MTD YTD Brewing Quality Index 12 Page MTD YTD
Consumer Quality
Index 14 Packaging Quality Index 12
Utility Quality Index 12
Raw Mat. quality Index

Below TGT
Par with TGT
Above TGT
Technical Quality Indexes are the internal
Strategic KPI – 3. Consumer Quality Index measurements of quality as per industry standards.
All the indexes are calculated OOS as a % of
3.1 Divisional Technical Quality Indexes samples analyzed.
12
Divisional Technical Quality Indexes

102.00
98.00
94.00
Quality Index (%)
90.00
86.00
82.00
78.00
74.00
70.00
Sep '09 Oct '09 Nov '09 Dec '09 Jan '10 Feb '10 Mar '10 Apr '10 May '10 June '10 July '10 Aug '10
Strategic KPI – 3. Consumer Quality Index
3.2 Brand Wise Quality Indexes
13
Brand wise Quality Indexes
102.00
98.00 Tgt. 95
94.00
Quality Index (%)
90.00
86.00
82.00
78.00
74.00
70.00
Sep '09 Oct '09 Nov '09 Dec '09 Jan '10 Feb '10 Mar '10 Apr '10 May '10 June '10 July '10 Aug '10
Strategic KPI – 3. Consumer Quality Index Index not ready
3.3 Consumer Quality Index
14
110.00
105.00
100.00
95.00
Quality Index (%)
90.00
85.00
80.00
75.00
70.00
65.00
60.00
Nov Dec Jan Feb Mar Apr May Jun Jul Aug
15
Strategic KPI – 4. Capacity Utilization
Page MTD YTD
Page MTD YTD Brewing Capacity Uti. 16 Opportunity loss due
to shortages Page MTD YTD
Capacity Utilization 4 Bottling Capacity Uti. 16 Cost of loss in Market
Canning Capacity Uti. share
16

Below TGT
Par with TGT
Above TGT
Strategic KPI – 4. Capacity Utilization
4.1 Brewing, Bottling & Canning
16
Plant Capacity Utilization

140.00
120.00
100.00
Utilization (%)
80.00
60.00
40.00
20.00
0.00
Strategic KPI – 4. Capacity Utilization Only average loads are taken for
these calculations.
4.2 Utility plants
17
Utility Plants Capacity Utilization

100
90
80
70
Utilization (%)
60
50
40
30
20
10
0
18
Strategic KPI – 5. Technical Innovations
Page MTD YTD
Page MTD YTD Number implemented 12 Page MTD YTD
Technical Innovations 4 12 Estimated Savings per
annum

Below TGT
Par with TGT
Above TGT
Strategic KPI – 5. Technical Innovations CSS plant & SB Recipe
5.1 Successful implementations
19
Impact of innovations on company profitability

60,000,000 CSS 2
Plant
50,000,000
40,000,000
30,000,000 1
20,000,000
10,000,000
0 -
PROJECT KPI– 1
20

Page MTD YTD
Page MTD YTD Rate of completion Page MTD YTD
KEY Projects Savings

Below TGT
Par with TGT
Above TGT
Some payments made as
Strategic KPI – 5. PROJECTS (contd.) advances have not yet been
5.2 Project Status settled. Hence project cost
pending.
% Completion of Project
21
1 2 3 4 5 6 7 8 9 10
Budget 206,000,000
Spent 186,000,000
End August 2010 FV/Lauter... 99%
Budget 65,000,000
Spent 36,300,000
Ref. P... 90%
End Aug 2010
Budget 54,000,000
Spent 22,000 CO2 P... 59%
End Pending
Budget 46,500,000
Spent 9,849,000 Water Tr... 89%
End August 2010
Budget 89,000,000
Spent 86,163,000 Power Su... 83%
End August 2010
Strategic KPI – 5. PROJECTS Raw material cost reduction – continuous activity.
Waste minimization – continuous activity
5.2 Project Status
% Completion of Project
22
1 2 3 4 5 6 7 8 9 10
Budget On ROI basis
Spent Waste Minim... 95%
End Sept 2010
Budget
RM cost reduc... 0%
Spent
End
0%
0%
0%
0%
Operational KPI – 1. Divisional Overheads
23
KPI Efficiency measure Cost

Page MTD YTD
Page MTD YTD Product Losses (Extract) 22 Page MTD YTD
Divisional Overheads Overtime as a % of total Divisional Overhead
working time Budget Vs actual
Utility consumption Cost of Spillages 28
Bottle Breakage 27 People variable cost
Packaging Efficiency 26 Spare parts inventory
Spare parts inventory 33
Below TGT
Par with TGT
Above TGT
Operational KPI – 1.1 Divisional Overheads (Brewing)
1.1.0 Divisional Overhead actual vs. budgeted (cumulative)
24
70,000,000.00 Budget Spillage calculation basis is different from actual
60,000,000.00 Finance agreed to change the calculation basis from next re-forecast
50,000,000.00
Divisional overhead (Rs)
40,000,000.00
30,000,000.00
20,000,000.00
10,000,000.00
0.00
Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar
Operational KPI – 1.1 Divisional Overheads (Brewing)
1.1.1 Product Losses (Extract basis)
25
1.60
Tgt. 3.70
1.40
1.20
1.00
0.80
Axis Title
Tgt. 1.20
0.60
0.40
0.20
0.00
Operational KPI – 1.1Divisional Overheads (Brewing)
1.1.2 Cost of Spillage
26
30,000,000.00
Finance agreed to change the calculation basis from next re-forecast
25,000,000.00
20,000,000.00
15,000,000.00
Axis Title
10,000,000.00
5,000,000.00
0.00
Operational KPI – 1.2. Divisional Overheads (Packaging)
1.2.0 Divisional Overhead actual vs. budgeted (cumulative)
27
160,000,000.00
140,000,000.00
Divisional overhead (Rs)
120,000,000.00
100,000,000.00
80,000,000.00
60,000,000.00
40,000,000.00
20,000,000.00
0.00
Operational KPI – 1.2 Divisional Overheads (Packaging)
1.2.1 Packaging Loss (Volume basis)
28
Packaging Loss
3.50
3.00
2.50
Loss (%)
2.00
Tgt. 1.50
1.50
1.00
0.50
0.00
Operational KPI – 1.2. Divisional Overheads (Packaging)
1.2.2 Packaging & Line Efficiency
29
Packaging & Line Efficiency

90.00
Tgt. 85.00
85.00
80.00
75.00
Tgt. 65.00
Efficiency (%)
70.00
65.00
60.00
55.00
50.00
45.00
40.00
Sep Oct Nov Dec Jan Feb Mar Apr May June Jul Aug
1.2.3 Packaging Line – Internal bottle breakages
30
Packaging Line Internal Bottle Breakages

1.40
As a % of total empties fed
1.20
1.00
0.80
0.60 Tgt. 0.50
0.40
0.20
0.00
1.2.4 Packaging Spillage
31
P a ck a g in g S p illa g e (R s)
14,000,000.00
Finance agreed to change the calculation basis from next re-forecast
12,000,000.00
10,000,000.00
8,000,000.00
6,000,000.00
4,000,000.00
2,000,000.00
0.00
Operational KPI – 1.3 Divisional Overheads (Engineering)
1.3.0 Divisional Overhead actual vs. budgeted
32
60,000,000.00
50,000,000.00
Div. Overhead (Rs)
40,000,000.00
30,000,000.00
20,000,000.00
10,000,000.00
0.00
F u r n a c e F u e l c o n s u m p t io n ( l/h l)
1.3.1 Furnace fuel consumption
33
5.00 60,000
4.50
Tgt. 4.20 50,000
4.00
3.50
40,000
3.00
2.50 30,000
2.00
20,000
1.50
1.00
10,000
0.50
0.00 -
E le c t r i c it y C o n s u m p t i o n ( k W h /h l )
1.3.2 Electricity Consumption
34
18.00 60,000
17.00
16.00
50,000
Tgt. 15.75
15.00
40,000
14.00
13.00 30,000
12.00
11.00
20,000
10.00
10,000
9.00
8.00 -
1.3.3 Water Consumption
35
8.00 60,000
Tgt. 7.00
7.00
50,000
6.00
40,000
Consumption (hl/hl)
5.00
4.00 30,000
3.00
20,000
2.00
10,000
1.00
0.00 -
Increase is as a result
Operational KPI – 1.3 Divisional Overheads (Engineering) of preparations for the
Annual shutdown
1.3.4 Engineering Spares inventory scheduled for July
2010.
36
120.00
115.00
110.00
Inventory (Rs. Millions)
105.00
100.00
95.00
90.00
85.00
80.00
75.00
70.00
Operational KPI – 1.4 Divisional Overheads (Quality Assurance)
D iv isio n a l O v e r h e a d (R s)
37
12,000,000.00
10,000,000.00
8,000,000.00
6,000,000.00
4,000,000.00
2,000,000.00
0.00
Operational KPI – 2. & 3. Pending audit issues
38

Page MTD YTD
Page MTD YTD Pending Internal NC Page MTD YTD
Pending Audit NC Pending External NC

Below TGT
Par with TGT
Above TGT
Operational KPI – 2 Pending Internal audit findings No Pending
3 Pending External audit findings issues
N u m b er o f N C
39
Pending Audit Issues

1
0
Brewing Packaging Engineering Quality Logistics
Operational KPI – 4 Hygiene Audit Score
40

Page MTD YTD
Page MTD YTD Brewing Page MTD YTD
Hygiene Audit Score Packaging
Engineering
Quality

Engineering Stores

Below TGT
Par with TGT
Above TGT
Operational KPI – 1.4 Hygiene Audit Score
E x p ec ted S ta n d a r d = 1 0 0 %
41
Hygiene Audit Score

140.0%
120.0%
100.0%
80.0%
60.0%
40.0%
20.0%
0.0%

Manufacturing KPI Review by CEO-Aug Final 10

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1

MANUFACTURING KPI REVIEW

Strategic KPI’s Operational KPI’s People development Project KPI’s

Page Page Page Page

KPI Efficiency Measurement Cost Measure

SKU Availability Index – %Variance against standard of 10 days FG inventory (reporting

KPI Efficiency measure Cost measure

Direct Raw Material Prices

Raw Material Cost/hl for SB SKUs

Divisional Technical Quality Indexes

Brand wise Quality Indexes

Plant Capacity Utilization

Utility Plants Capacity Utilization

Impact of innovations on company profitability

KPI Efficiency measure Cost measure

KPI Efficiency measure Cost

Packaging & Line Efficiency

Packaging Line Internal Bottle Breakages

0.60 Tgt. 0.50

KPI Efficiency measure Cost measure

Pending Audit Issues

KPI Efficiency measure Cost measure

Hygiene Audit Score

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