jo-na’s international philippines, inc. green productivity demonstration program jo-na’s intl....

No Slide TitleGREEN PRODUCTIVITY DEMONSTRATION PROGRAM JO-NA’S INTL. PHILS., INC.
erick
1000.unknown
Jo-na’s International Philippines, Inc.
Jo-na’s International Philippines Incorporated, from its humble beginning and modest operations that started in 1981, has become one of the country’s pioneers in Food Preservation and Banana Chips Making. The company later expanded and recorded countrywide success in the manufacture of snacks and dehydrated and preserves fruits.
erick
Bolstered by its wide acceptance in the local market, Jo-na’s ventured into export barely a year after it began operations. It started shipping the locally manufactured Banana Chips to the United States, Canada, Europe, Japan and other Asia Pacific Countries. Since then, Jo-na’s has expanded operations to become of the biggest exporters and suppliers of premium quality Banana Chips.
erick
To cope with global trends, competition and changing consumer demands Jo-na’s continue to conduct extensive studies and researches, and at the same time engage in aggressive product development programs. It maintains seasoned Food Experts, Technicians and Quality Control Personnel to always ensure the quality of its product.
erick
It has also undertaken measures and strategic moves to expand its source of raw materials thereby making the company known for its ability to meet its export commitments.
Jo-na’s is known to pioneer in introducing Nata de Coco in Japan and was be able to pass its consumers high quality standard expectations and discriminating taste.
erick
Up to present, Jo-na’s Nata de Coco is one of the leading brands in the Japanese Market.
Towards the 1990’s, Jo-na’s started to strengthen its position in the local snacks market by introducing new products that revolutionize the snacks industry.
erick
Our Products:
Tropical Fruit Preserves
Awards
Jo-na’s International Philippines Incorporated has consistently been nominated in various domestic, International Awards like, the International Awards for Food and Beverage.
The company was awarded with the very prestigious Annual National Export Award, the Golden Shell Award in 1989 for its Excellence in Export Marketing , and the Industry Partner Awards by Industrial Technology Development Institute - Department of Science and Technology
erick
Export Market
Jo-na’s products are now widely visible in Aruba, Australia, Belgium, Canada, Denmark, Dubai, France, Germany, Greece, Hong Kong, Iceland, Israel, Italy, Japan, Kingdom of Saudi Arabia, Korea, Kuwait, Lebanon, Netherlands, New Zealand, Paris, Singapore, Spain, Sweden, Taiwan, United Kingdom, United States of America, and etc.
Local Market
Jo-na’s products are nationwide visible Metro Manila, South & Northern Luzon, Visayas Region and Mindanao Region
erick
QUALITY POLICY
Continues search for quality products and process improvements through Research and Development
Building competency, quality conscious and reliable work teams
Nurturing business partnership with our customers, suppliers and creditors.
erick
ENVIRONMENTAL POLICY
Jo-na’s International Phils., Inc. a manufacturer of Tropical fruits preserves, Noodles, and Snackfood products is committed to the well being of the family members and conservation of the life-sustaining resources. It is our policy to qualify all work processes so that activities are ecologically sound.
Recognizing the profound impact of our activities to the people and natural environment we undertake the following measures to realize our fundamental policies;
erick
COMPLIANCE
We commit to comply to all applicable laws and regulation and other requirements pertaining to environmental impacts of the organization’s activities, products and services .
Correspondingly, we will employ and comply to a safe and healthy operating systems, procedures and processes.
erick
PREVENTION OF POLLUTION
We will adopt a pollution prevention program focused on reduction, re-use, and recycling of raw materials and wastes to protect life, property and the environment, especially for the discharge of waste water, emission of polluted air, and discharge of waste to land.
erick
CONTINUAL IMPROVEMENT
> Conserve natural resources
> Ensure that all significant aspects and regulations are considered in setting up our environmental objectives and targets
We Will:
CONTINUAL IMPROVEMENT
> Ensure that all personnel involved in the organization’s operations have appropriate training, each individual concerned understands the significant aspects and its corresponding impacts
> Provide a mechanism to ensure that our employees, business partners, distributors and suppliers are made aware of this commitment.
This environmental policy will be made publicly available.
We Will:
erick
We develop nutritious, safe and affordable food products that cater to the increasingly discriminating tastes of people of all ages.
We constantly improve on our standard quality products that have become everyday favorites and spawned a wide supporting cast of equally delightful and high quality food products.
MISSION STATEMENT
VISION STATEMENT
We are people oriented. Consumers, Distributors, Suppliers, and Employees are partners in our growth and future.
We are resource oriented. Employees are productive and work best in an enlightened and supportive environment.
We constantly improve on quality standard of our products.
erick
VISION STATEMENT
Wide acceptance of our products inspires us more and edifies all of us at JO-NA’S as well as our distributors and suppliers for we become effective instruments of GOD ’s abundance, goodness, and wisdom.
We believe in the high worth and quality of our food products.
Our business philosophy and self-esteem set us apart
erick
VISION STATEMENT
Our social responsibility includes active participation in the preservation of ecological balance and environmental concern.
erick
- Joyful in our task
70% - Female 30% Male
TOTAL HEAD COUNT
5S Program
3. 5S evaluators
5S Program
5S Program
Evaluation/Inspection Committee
5S Program
1. Does the evaluation schedule for the
month
3. Coordinate to Team leaders result of
evaluation
2. Review the results
3. Prepared Corrective actions
committee head
erick
5S Program
Head per team
2. Reviews the results
3. Prepares corrective actions
committee head
erick
5S Program
Evaluation/Inspection Committee
erick
and winning team sections receives token, like
5S Program
Awarding/Recognition Committee
* office/dry production - 90% above
1. Preparation of Bi-monthly Inspection result per
area
department.
is done during, first Wednesday
of the Month, general assembly
(all employees assigned to participating
umbrella, towel etc.)
and winning team sections receives token, like
5S Program
Awarding/Recognition Committee
3. Awarding of 5'S Banner and token to the monthly
5S Champion
umbrella, towel etc.)
Value Formation Program
ONCE A MONTH
(7:30 - 9:00 am)
Employees
from the (old
5. General Announcement
2. Achievements
6. President's segment
about the quality and productivity issues/concerns)
employees - young once)
ONCE A MONTH
(7:30 - 9:00 am)
2. Achievements
6. President's segment
about the quality and productivity issues/concerns)
erick
4. Commentary
commentary
5. Communicating the Company
7. Communicating the goal for
the week of each section/department,
to all employees
7. Communicating the goal for
the week of each
Green Productivity Program
SPONSORED BY:
(Productivity Development Center)
What is Green Productivity?
GP is a strategy for enhancing productivity and environmental performance for overall socio-economic development. It is the application of appropriate productivity and environmental management tools, techniques & technologies to reduce the environmental impact of organization’s activities, goods and services.
erick
GP concept aims to ensure environmental protection while making business profitable. It focus on quality, profitability and environment. The Practice of GP will result to effective use of resources such as (man, machine, material, method) including fuel, energy and keeping the quality of environment.
erick
“DOING MORE FOR LESS”,
> Reduce / Recycle the water consumption
> Reduce the energy/fuel consumption
> Reduce man hour usage
erick
Why Jo-na’s Needs GP Program?
No detailed plan to really focus on the pollution prevention, energy conservation, and process improvement
Our operations process uses a lot of water about millions of liters per month
Our electricity / energy / fuel cost is high
Our garbage disposal cost is high
Our product cost is high due to low efficiencies, a lot of rejections, wastages in the processes
erick
Our waste water treatment plant is not complying with the standard
Our people are lack on technical expertise in managing our environmental responsibilities
To improve company profitability
erick
GP PROGRAM
TOP MANAGEMENT
erick
Organization:
a. Process improvement team
b. Energy Conservation Team
erick
Organization:
GP Methodology:
root causes/Work shop/Training
4. Solution Formulation/
erick
GP Methodology:
7. Monitoring and Review
8. Sustaining GP(incorporating changes
(ISO14001 system)
Step 1 Getting Started
2. Walk Through Survey
Collection of baseline information
b. Interview the operators, workers assigned
in the working area
erick
3. Identify Problems and root causes,(Man, Machine, Material, Method).
a. Fish bone analysis/Ishikawa Diagram
b. Ask 5 times WHY?
Step 2 Planning
a. SMART - Specific, Measurable, Attainable, Realistic, Time bound
erick
erick
Lack of awareness of responsibility
Poor maintenance
erick
Continuos outflow
Continuos outflow
Pending repair
Lack of awareness
EVALUATION OF GP OPTIONS
1. Controllable - GP options that can immediately fix, repair, implement without high cost needed, 10,000.00 below
2. Uncontrollable - GP options that cannot be
immediately fixed, repaired, with investment cost of more than =P= 10,000.00 pesos, need cost and
benefits analysis with payback period of projected savings.
Step 3 Generation and Evaluation of GP Options
erick
Example chart EVALUATION OF GP OPTIONS
erick
data1
INPUT
PROCESS
OUTPUT
INPUT
PROCESS
OUTPUT
received with
received with
Example illustration of uncontrollable GP options:
GP options: Installation of Water recycling system
Cost of investment
GI Pipe 1 1/2 9 pcs =P= 570.00 =P= 5,130.00
GI Pipe 2’’ 8 pcs. 700.00 5,130.00
Elbow 2’’ 12 pcs 60.00 720.00
Tee 2’’ 6 pcs. 75.00 450.00
Check valve 2’’ 1 pc 365.00 365.00
Water Pump 2 HP 1 pc 16,000.00 16,000.00
Tank(10,000 liters) 30,000.00 30,000.00
Labor cost(piping installation) 5,000.00
After recycling plan 1,207.08 cu.m./year 48,297.60
Savings in water/year 8,207.44 cu.m/year 338,083.20
Cost of Investment 63,265.00
note: 1 liter = P=0.04 or 1 cu.m = P40.00
Other benefits are not yet quantified and costed but includes the reduction of water to be treated at WTP.
erick
Example illustration of uncontrollable GP options:
GP options: Installation of Water recycling system
Cost of investment
GI Pipe 1 1/2 9 pcs =P= 570.00 =P= 5,130.00
GI Pipe 2’’ 8 pcs. 700.00 5,130.00
Elbow 2’’ 12 pcs 60.00 720.00
Tee 2’’ 6 pcs. 75.00 450.00
Check valve 2’’ 1 pc 365.00 365.00
Water Pump 2 HP 1 pc 16,000.00 16,000.00
Tank(10,000 liters) 30,000.00 30,000.00
Labor cost(piping installation) 5,000.00
After recycling plan 1,207.08 cu.m./year 48,297.60
Savings in water/year 8,207.44 cu.m/year 338,083.20
Cost of Investment 63,265.00
note: 1 liter = P=0.04 or 1 cu.m = P40.00
Other benefits are not yet quantified and costed but includes the reduction
of water to be treated at WTP.
erick
Step 4. GP OPTIONS / IMPLEMENTATION PLAN
Objective 1:
regulations:
work
Step 4. GP OPTIONS / IMPLEMENTATION PLAN
Energy Conservation Program Committee
Water & Oil Conservation Program Committee
Solid Waste Management Committee
Team Leader
1. Qualities of the team leader:
Should be available to devote time, accepts
extra responsibilities
4. Good Motivator
6. Ability of organize the task
7. Ability to implement commitment
8. Good communicator
9. Good listener
12. Ability to do documentation and make a report
13. Results Oriented Person
2. Each Implementing Committees need to organize their own organization structure, to compliment the
success of the program, to divide the duties and responsibilities to all team members.
3. Monthly Review will be conducted to monitor the progress of the committee activities.
4. All GP Options that will require capital investment need to present the cost and benefits / payback period.
erick
PROCESS IMPROVEMENT PROGRAM:
a. Man
b. Machine
c. Material
d. Method
* GP OPTIONS:
erick
PROCESS IMPROVEMENT PROGRAM:
5. Achieved better quality products and higher productivity by reducing environmental aspects and impacts.
erick
GP OPTIONS/STRATEGIES:
the following objectives:
- to reduce water & oil consumption thru;
1. Thru Good Housekeeping by fixing all leaking pipes, change the diameter of hoses, faucet, instill strict discipline to the workers
2. Standardize the use of water for each process, put reminders/visual
3. Installation of water meter, recycling system, oil recycling system
4. Upgrading of Waste Water T. Plant
> Modification of the design,
> reduce WTP operating cost
erick
BENEFITS:
2. Reduce waste water discharge to WWTP, compliance to waste
water discharge & environmental regulations.
3. Consumption is monitored and measured.
4. Continues study and search on how to reduce water & oil
consumption.
& monitor consumption
objective of implementing the following /GP Options:
Waste Segregation System;
generated from the source (production line)
d. Introduction of re-use, re-sell, recycle
* Formed a team that handles the Solid Waste Management Program
Solid
BENEFITS:
Waste within the organization.
2. Reduce garbage (hauling expenses and disposal fees to land fill) and Volume of Garbage being disposed to land, compliance to environmental regulations.
3. Reduce Generation of Waste per line
4. Rejection per line is monitored & Analyzed (with target reduction of rejection).
5. All kinds of Dry waste are sold to junk shop except for foil.
Solid
Objective;
a. Thru good housekeeping;
* steam pipes leaks repair,
motors
d. Maximize the capacity of each machines (full capacity loading).
* * Formed a team that handles theEnergy Conservation Program.
ENERGY CONSERVATION PROGRAM
BENEFITS:
2. Improve safety within the organization
3. Consumption/usage is periodically reviewed and analyzed
4. GP team has the knowledge to measure and monitor consumption
5. Reduce the electricity consumption, fuel consumption (LPG,Diesel,Bunker)
ENERGY CONSERVATION PROGRAM
Step 5. MONITORING AND REVIEW
A. Monthly Monitoring of each Team’s activities and results of GP Options Implementation
1. Once a week meeting of Team members
2. Bi-monthly meeting of Core Team
3. Once a month meeting / reporting to Top Management of the GP Implementation Plan
progress status and measured results and achievement
erick
MEASURED BENEFITS
SUMMARY OF MEASURED SAVINGS
(all dry waste can be sold except for
= P= cost
=P= cost
(waste cans)
aluminum foil)
(11 % decrease)
(January - August)
total cost:
total cost:
4,903,554.18
4,014,391.50
889,162.68
111,145.35
=P=
=P=
=P=
=P=
=P= 147,000.00
=P=147,000.00
note: The penalty and waste water
note: our waste water treatment plant has been upgraded, operations only started last week.(5/24)
contractor
in the computation of savings.
Operating cost
note: our waste water treatment plant has been upgraded, operations only started last week.(5/24)
Sheet2
Sheet3
erick
Sheet7
wwtp
Waste Water Analysis Comparison
WTP-Process
electricity consumption
Equalization tank
minimal cost
Purchased Transfer Pump
Garbage Collection Fees
2001 vs 2002
Water Usage comparison
2001 vs 2002
2001 vs 2002
unit: Cubic Meter
Electricity Cost - in terms of '=P= Peso value
2001 vs 2002
October
- 0
- 0
- 0
November
- 0
- 0
- 0
Electricity Usage (kW) comparison
savings:
Months
2001
2002
July
0.234
0.21
0.024
October
0
November
0
December
0
Efficiency comparison
December
0
November
0
total
52.52
49.36
-3.16
%savings( )unfav/favorable
erick
Sheet7
wwtp
WTP-Process
Equalization tank
minimal cost
2001 vs 2002
2001 vs 2002
2001 vs 2002
unit: Cubic Meter
2001 vs 2002
October
- 0
- 0
- 0
November
- 0
- 0
- 0
2001 vs 2002
unit rejection/case '=P=
Bunker Fuel Usage (liter) comparison
2001 vs 2002
savings:
Months
2001
2002
August
0.2006
0.1961
0.0045
savings:
Months
2001
2002
July
0.234
0.21
0.024
October
0
November
0
December
0
November
0
total
52.52
49.36
-3.16
erick
Sheet7
wwtp
WTP-Process
Equalization tank
minimal cost
2001 vs 2002
2001 vs 2002
2001 vs 2002
unit: Cubic Meter
2001 vs 2002
October
- 0
- 0
- 0
November
- 0
- 0
- 0
savings:
Months
2001
2002
July
0.234
0.21
0.024
October
0
November
0
December
0
December
0
November
0
total
52.52
49.36
-3.16
erick
Sheet7
wwtp
WTP-Process
Equalization tank
minimal cost
2001 vs 2002
2001 vs 2002
2001 vs 2002
unit: Cubic Meter
2001 vs 2002
October
- 0
- 0
- 0
November
- 0
- 0
- 0
savings:
Months
2001
2002
July
0.234
0.21
0.024
October
0
November
0
December
0
December
0
November
0
total
52.52
49.36
-3.16
erick
Sheet7
wwtp
WTP-Process
Equalization tank
minimal cost
2001 vs 2002
2001 vs 2002
2001 vs 2002
unit: Cubic Meter
2001 vs 2002
October
- 0
- 0
- 0
November
- 0
- 0
- 0
savings:
Months
2001
2002
July
0.234
0.21
0.024
October
0
November
0
December
0
December
0
November
0
total
52.52
49.36
-3.16
erick
WTP-Process
Equalization tank
minimal cost
2001 vs 2002
2001 vs 2002
2001 vs 2002
unit: Cubic Meter
2001 vs 2002
October
- 0
- 0
- 0
November
- 0
- 0
- 0
2001 vs 2002
unit rejection/case '=P=
Bunker Fuel Usage (liter) comparison
2001 vs 2002
savings:
Months
2001
2002
August
0.2006
0.1961
0.0045
savings:
Months
2001
2002
July
0.234
0.21
0.024
October
0
November
0
December
0
November
0
total
52.52
49.36
-3.16
TOTAL
SAVINGS
=P=
1. Garbage disposal (Jan-August)19 truck loads of garbage 3 truck load of garbage cost of paint: '=P= 1,000.00
(all dry waste can be sold except for= P= cost=P= cost(waste cans)
aluminum foil)60,518.18 10,081.82 60,518.18 7,564.77
unit rejection/case'=P=unit rejection/case'=P=
2. Production Rejects(Jan-July)1.086 0.975 negligible/minimal cost
(please refer to separate data sheet) (11 % decrease)
(Packaging mat and Raw materials)total cost:total cost:
640,401.60 519,087.50 121,314.11 17,330.59
kg output/hr kg output/hr
(please refer to separate data sheet) ( 6 % increase in eff.)
liters used/kilo outputliters used/kilo outputcost of:pipes-stainless,hose
4. Water consumption(Jan - April)14.8811.31 hose (small diameter),=P=10,000.00
( 34.65 % decrease) recycling ssytem:
581,452.80 500,572.80 80,880.00 10,110.00 payback: 8 months
5. Electricity Consumptionkwh used/kilo outputkwh used/kilo outputcost of : rewiring, motors,
(January - April)0.201250.179675 Y delata connection.
(11 % decrease ) =P= 150,000.00
1,025,388.00 846,350.04 179,037.96 44,759.49 payback: 3.35months
6.Fuelliters used/kilo outputliters used/kilo output* note: with change on process (retorting temperature from
Bunker fuel (January-April)0.1944750.191675105 degrees to 120 degrees, month of March to April
(1.5 % decrease)* no savings in terms of ' Peso value
note: to improve the cone design ofcost:=P=cost:=P=this means that the cost of per unit kilo went up
firing tube, installation of pre-heater1,404,485.72 1,657,850.92 (253,365.20) (from =P9.42/liter to 11.00/liter)
for feed water not yet installed.
LPGliters used/kilo outputliters used/kilo output
(January - March)0.06400.0645no savings from peso value, this means that
.07 % increasecost of per unit kilo went up, from "P18.47/liter
note: GP options not yet cost:to '=P=25.00/liter)
implemented327,002.12 227,213.50 (99,788.62)
7. Waste Water operationsaverage influent:average influent:20- 30 cu/daycalculation of savings on operating
70-80 cubic meter/day50 -60 cubic meter/daycost against investment is not yet
note: our waste water treatment plant has been upgraded, operations only started last week.(5/24) computed
Indicators
2001
(all dry waste can be sold…

jo-na’s international philippines, inc. green productivity demonstration program jo-na’s intl....

Documents