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EMPOWERED
OPERATORS
Şahin Keykan
CCI Ankara Plant Manager
Share Best Practice Conference
Dubai
September 29, 2013
Coca-Cola İçecek
1964 Turkey meets Coca-Cola
Foundation of MAKSAN and
buys ANSAN.
1988
Foundation of CCBT 1 January,1998
CCBT takes the brand name,
1 January,2003
• 6th largest bottler in the Coca-Cola System in terms of sales volume
• Employs more than 9,000 people and has operations in Turkey, Pakistan, Kazakhstan, Azerbaijan, Kyrgyzstan, Turkmenistan, Jordan, Iraq and Syria, as well as exports to Tajikistan
• Total production capacity 6.8 billion liters (1.2 billion uc)
• Total sales 4.3 billion liters
• Net Sales Revenue USD 2 billion
About CCI
• Located in Ankara, Capital of Turkey
• Established in 1973 on an area of 63,000 sqm
• Total production:
– Beverage: 390 million liters / 34 million physical cases
– PET Bottle: 257 million bottles
– PET Preform: 176 million preforms
CCI Ankara Plant
(CSD)
(Carbonated Soft Drink)
Cola Segment
Flavoured Drinks
(NCB)
(Non-Carbonated Soft Drink)
Fruit Juices and Nectars
Energy Drink
Ice Tea
Sport Drinks
Bottled Water and HOD
Mineral Water
CCI AP
Products
Ankara Plant Employees
• 123 permanent, 40 seasonal
• Breakdown by Position – Managers %2
– Engineers/Administrative %5
– Operators & Foremen %85
– Other %8
• Average of Age: 34
• An integration of management systems: – ISO 9001 Quality Management System
– ISO 14001 Environmental Management System
– OHSAS 18001 Occupational Health and Safety Management System
– ISO 22000 Food Safety Management System
– ISO 50001 Energy Management System
– FSSC 22000/ISO 22002-1/PAS 223 Standard for Food and Package Safety
– KORE (The Coca- Cola Company Requirements)
– Local Regulations
– CCI 2020 Vision
– TPM ( Total Productive Maintenance ) & 5S
– Integrated Process Approach
– Operational Excellence, Lean Six Sigma
– EFQM Excellence Model
CCI’s Integrated System
CRITERION NO: 3 PEOPLE
3c. People are aligned , involved and empowered.
For example , excellent organisations :
• Align personal and team objectives , and empower people to realise their full potential in a spirit of true partnership.
EFQM Excellence Model 2013
• Qualified and well trained who knows and follows up legal and quality needs within CCI’s integrated system in his/her processes
• Trained for the purpose of reaching engineer qualification level in his/her task
• One of the main role players in excellence journey
CCI’s Empowered Operator
Tasks of Empowered Operators
Regular Task: Performing the operation of the machine
Qualified Task: Maintain, follow, measure, monitor and apply requirements of quality, safety and environmental systems Participate to innovation and improvement, and work as a part of the team as suggested by the EFQM Model
• Is responsible of the maintenance of the machine and spare parts tracking
An Empowered Operator
Maintenance of a machine within TPM framework by a labeling operator
Autonomous maintenance approach and spare parts tracking are being performed by the operator
• Is responsible for the GMP application to the machine and his/her working area
An Empowered Operator
Operator cleaning his labeling machine
Cleaning and maintenance zone responsibilities are specified for each operator and monthly GMP assesments are performed
An Empowered Operator
Filling m/c operator controls net content value of a product
Caps torque measurement
Measures chlorine content of the rinsing water
• Performs basic QC Tests
• Executes within the framework of management systems:
– Coca-Cola requirements (KORE), quality, food safety, FSSC 22000 (ISO 22002-1 and PAS 223), EOSH , EFQM Excellence Model
An Empowered Operator
Filling m/c operator collects hazardous wastes into the container
An Empowered Operator
Blowing m/c operator fills production report in SAP next to his machine.
Operators are able to track and analyse the result of data previously entered into SAP.
• Uses SAP
• Follows plant and line level KPIs
An Empowered Operator
Labelling m/c operator checks the label yield at his machine
Palletizing m/c operator checks the weight of stretch film
usage of a pallet and calculates the stretch film yield
Process owners share the KPI’s status with the empowered operators and management in periodic intervals. This helps to increase the awareness among operators and enhances continuous improvement.
• Is aware of the production process (Process Approach)
An Empowered Operator
An Empowered Operator
Operators develop and implement suggestions and projects to
increase efficiency and improve the processes
Kaizen improvement projects are performed by the foreman and
operators. These projects compete at CCI Innovation Competition and
National Quality Chamber Projects Competition
• Participates in innovation and OE projects
• Focuses on customer / consumer
An Empowered Operator
Empowered operators attend to «Sales Blitz» activities with the sales force and visit the customers and Sales Points in order to increase Customer/Consumer Focus.
An Empowered Operator
• Is involved in management activities – Delegated participation in departmental summits
– Participation in decision making on issues such as EOSH, food
safety, social activity, meal menu, work clothes quality & style
• Participation in Go to Gemba Meetings
• Participation in Management Review Meetings and Process Presentations
An Empowered Operator
Tree plantation feast day with the participation of all employees
Blood donation to Red Crescend
- Act with integrity - Be honest - Follow the law - Comply with the Code of Business Conduct - Be accountable
• Values social responsibility and ethics As a responsible corporate citizen, we care about the needs and expectations of the local communities everywhere we operate and support solutions that are responsive to individual community needs.
An Empowered Operator
The operators are expected to reflect good company image with their behavior and personal hygiene
• Reflects the good company image
• Has fun while working
An Empowered Operator
Ankara Folk Dance Team Outdoor activities
Picnic organizations with all employees and their families.
Football tournament
• Is highly engaged to the company
– Measuring satisfaction & engagement annually
– Comparison of plant results to CCI operations, best companies in Turkey, FMCG companies in Turkey and Central Europe and Eurasia.
– Action plans for improvement
An Empowered Operator
• MEX – Maintenance Excellence Training
– Theoretical and practical trainings in machine maintenance
– 30+ topics
– Examples: high pressure compressor, mechanical filler, bottle blower, bearings, machine oils
• Core Requirement Trainings
– The Coca-Cola Quality Standards
– Occupational Health & Safety
– Environmental Management
– Food Safety
Enabling Trainings
• Soft Skill Trainings
– Teamwork
– Problem Solving & Innovation
– Communication skills
• Competency Level Trainings
– Machine operation competency-on the job training (OJT)
• e-learnings
– Computer based self trainings
– Examples: safety, environment
Enabling Trainings
MUSTAFA ÇOBAN
BURHAN ÇINAR
LINE-1
PAC
KER
PALL
ETIZ
ER
BO
TTLE
WA
SHER
CASE
WA
SHER
EMRE BAŞTAŞ
BO
TTLE
DEP
ALL
ETIZ
ER
AIR
CO
NV
EYO
R
RIN
SER
FILL
ER
MIX
ER
LAB
ELLE
R
Competency Level Measurement
Can operate the machine by himself Can train anyone about the machine Can deal with daily, weekly, monthly maintanence
Can deal with yearly maintenances Can deal with any kind of maintenance Knows EOSH and food safety impacts Applies process documents, follows up KPI's
No experience and knowledge about the machine
Have basic knowledge, can help operator Knows machine structure and features Knows EOSH and safety issues about the machine
Can deal with some mechanical maintenance Can deal with machine process parameters Can fill operation forms of machine
Benefits
• High production efficiency
• High quality
• High material yield
• High employee engagement
• Minimum downtime and breakdown
• Minimum workplace accidents
• Low manufacturing cost