lanner client britvic discuss their leeds factory & warehouse simulation

Neil Brinkman, David RiceBritvic Soft DrinksLeeds factory & warehouse simulation

Agenda

• Introductions• Introduction to Britvic• Simulation overview• Project overview• Findings\summary

Making life’s everyday moments more enjoyable

Leading branded soft drinks business

More than 30 brands

More than 30 brands

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

Leading branded soft drinks business

£1,321.9mGroup revenue

Source: Britvic Plc Annual report 2013

Leading branded soft drinks business

3,300employees

Leading branded soft drinks business

2,066.9mlitres per year

Source: Britvic Plc Annual report 2013

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

Owned brands in UK

Franchised brands in UK

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

The simulation challenge

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.

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

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

Leeds - Skyfall New loading bays

New warehouse

New staff & visitor parking

New trailer parking

New production Line

Existing production lines (3)

Gatehouse

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

Beginning to see the output from the modelling…

One way system out into the loading bayTraffic flows in to the warehouse

Beginning to see the output from the modelling…

Warehouse starting to take shape Loading bays – nearly ready for use

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

Any questions?