gsc meeting pm - final

GSC MENEATTanzania Factory

David NderimoRegional GSC meeting, March 12-16, 2012

Engineering – Project Management

© Copyright JTI 2012

Engineering – Project management

Engineering - Project Management

Organization chart

Martin MARIKIProject Engineer

Shabani WAZIRIDraftman

David NDERIMOProject Manager

Martin PORTZProject EngineerSTA

Recently completed projects

3Engineering - Project Management


Factory water network

• Replacement of worn out 50 years old water network

• Connecting of 3rd borehole to water network

• Installation of water softener

• Implementation of water flow meter for monitoring

4

Completed in February 2012



Partial upgrade of new site warehouse

• Upgrade of part of semi finished warehouse (Mezzanine) with a total area of 1,800m² out of 10,000m²

• Operation with automatic exhaust heat fans

• Using natural light (Transparent sheets)

• Hygienic condition surface floor

• The warehouse is now used for tobacco storage

5

Completed in January 2012



Extension of fire detection system to

• Parts of newly installed Primary (Flash dryer)

• TP filter room

• Upgraded warehouse

• Fire pump area

Fire detection system extensionCompleted in January 2012


Projects in progress



2nd gas engine

• Description• Installation of additional 1MW electricity generating capacity to meet increased energy demand due to

new Primary and additional Make/Pack machines

• Goal• Ensure stable and sufficient power supply to support volume growth

• Status• Preparation works in progress

• Engine delivered; Synchronization panel in transit

• Key equipment installation start: 04/12

• Commissioning: 05/12

Marketing budget



Make/Pack and Cutfiller Storage HVAC

• Description• Extension of existing HVAC system in Make/Pack due to increased area and heat load

• Replacement of existing Cutfiller AHU due to increased storage area

• Goal• Improve machine performance

• Improve product quality

• Be in line with policies and procedures

• Status• Preparation works in progress

• Key equipment partially delivered; rest expected to be cleared by mid of March 2012

• Installation start: 04/12


ASP 2011-2012


© Copyright JTI 2012 10

New cutfiller AHU New Make/Pack AHU

Exisiting Make/Pack AHU Engineering - Project Management


Boiler Replacement and Co-generation

• Description• Replacement of one old boiler and making use of waste heat of gas engine #1

• Waste heat recovery of engine #2 not in scope

• Goal• Reliable and cost efficient steam supply

• Possible funding by Belgium government (subsidy directly paid to supplier) up to 50% of the equipment with a maximum of 247.500 Euro

• Status:• Application for subsidy: 01/12

• Feedback for subsidy: expected in 03/12

• PO: 04/12 (after feedback for subsidy)

• Installation: 10/12


ASP 2011-2012



New boiler house

Existing boiler house



KDF line

• Description• The current situation with JTI Tanzania is having two Filter makers (Rebuild KDF 2ER and KDF 2

overhauled by HAUNI)

• While the volume growth in make/pack has made an increase of the filter demand, it is necessary to increase the capacity in the filter production to avoid the risk of having insufficient filter supply to the makers and lowering the loading level to below 95%.

• Goal• Avoid overtime

• Meet volume demand

• Status:• Future Make/Pack layout to be finalized and agreed with production

• Machine in transit; expected to be cleared by mid of March 2012



ASP 2012



Printers for export product

• Description• Democratic Republic of Congo (DRC) requires printing of three lines on each pack

(Date of Manufacturing, Date of Expiration and Lot number of the product)

• Current domino ink jet printers do not have the capability of meeting this requirements

• Therefore two X500 packing lines need to be equipped with new printer

• Goal• Meet regulatory requirements for DRC market

• Status:• Original delivery time 04/12

• New delivery time 07/12 (Delay of 2 month)


ASP 2011-2012



4th GD 121/X 500 line

• Description• Installation of additional soft pack line (GD 121-AF 12, GD B 21, GD X 500, GD C800 and Taurus filter

mass flow) to provide sufficient capacity to cope with the increasing volume demand - driven by both the Tanzania domestic and East African markets

• Goal• Reduce loading level of soft pack lines

• Increase flexibility in production

• Meet market volume demand as per ASP

• Status:• Future Make/Pack layout to be finalized and agreed with production

• FAT / pre-inspection: 07/12



ASP 2011-2012


Planned projects



GD X2 electronics update

• Description• Replacement of obsolete Micro I plc control

• Goal• Ensure availability of machine

• Status:• Quotation from GD on hand

• BAP prepared and on internal circulation expected to be submitted by end of March 2012

• BAP approval: 04/12

• PO: 05/12



ASP 2012-2013



Rejects and Shorts buffering

• Description• Installation of rack system in production area to generate space for Rejects and Shorts to avoid outside

buffering

• Goal• Reduce material handling

• Optimize work flow

• Status:• Layout change of QC lab extension


TP Upgrade



Shorts tipper

Shorts buffering

QC extension


Outlook / focus areas



Primary

• Utilities• Steam pipe

• Waste water drainage

• Segregating Primary from outside• Emergency exits / doors

• Roller shutters

• Roof insulation

• Windows

• Ventilation system

Pending issues



Reduction of idle times in Primary

• Description• Lamina and CRES line are in direct connection via two old silos, but of non-matching capacities

• High idle times on Lamina line waiting for CRES

• Goal• Reduce idle times ( reduction of working hours and energy need)

• Optimize operation

• Status:• Alternative 1: CRES buffering in C-48 and adding back via tipper

• Alternative 2: Replace existing two old silos by two new double layer silos (in total 4 silos)

• Next steps• Conduct feasibility study to investigate different alternatives in detail

• Share results: 04/12

Study



CRES box off CRES silos

Addback tipper



New concept for batch preparation

• Description• Due to limited space inside Primary tobacco batches are prepared and stored outside

• This causes a lot of fork lift traffic as well as limited overview

• Goal• Reduce handling

• Optimize operation

• Increase safety on site

• Status:• Alternative 1: Convert old boiler house

• Alternative 2: Convert former heavy fuel oil storage

• Next steps• Conduct feasibility study to investigate different alternatives in detail


Study



Former heavy fuel oil storage Boiler house



Finalizing semi-finished warehouse on new site

• Description• Due to limited storage capacity Tanzania factory is renting outside storage

• Required space: 20,350 m2

• Available space: 11,819 m2

• Deficit: 8,531 m2

• Goal• Provide sufficient storage capacity for NTM, FG and tobacco on site

• Status:• Available space to be completed is 8,400 m2

• Estimated cost of work to complete is $ 2,132,750 (at the cost 250$/m²)

• Next steps• Conduct feasibility study to investigate in detail


Study


The future of Project Management section



The future of Project Management sectionThe department will merge as per ‘JTIs best practice’

Draftsman

Maintenance ENGINEER

Engineering MANAGER

Utility ENGINEER Project ENGINEER



David Nderimo

The department will merge as per ‘JTIs best practice’


EnterprisingOpenChallenging

gsc meeting pm - final

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