«trade company «rus-steklo» .pdfllc rus-steklo and manufacturers form their relationship on a...
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Limited liability company
«TRADE COMPANY
«RUS-STEKLO»
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LLC «TRADE COMPANY «RUS-STEKLO»
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Trade Company “Rus-Steklo” realizes glass tare manufacturedby 4 production plants:
• LLC “Sergiev Posad glass factory”,• LLC “Omsk glass factory”,• LLC “Kingisepp glass factory”• LLC “Velikodvorsky glass factory”.
LLC Rus-Steklo and manufacturers form their relationship on acontract basis.
The capacities of manufacturers completely satisfy the demandsof LLC Rus-Steklo.
Exclusive jar and bottles are objects of intellectual property andare manufactured only under orders of LLC Rus-Steklo.
LLC «TRADE COMPANY «RUS-STEKLO»
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Company’s share at the Russian market is 22%
Omskglass factory
Sergiev Posadglass factory
Velikodvorskyglass factory
Kingisseppglass factory
GLASS FACTORIES
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Provide glassware to the domestic and foreign customerssurpassing their expectations
MISSION:
Sergiev-Posad glass factory –
design capacity 800 mln pcs. of glassware peryear
Kingissepp glass factory – design capacity680 mln. pcs. of glassware per year
Omsk glass factory – design capacity390 mln. pcs. of glassware per year
Velikodvorsky glass factory – design capacity200 mln. pcs. of glassware per year
PRODUCTION RESULTSPRODUCTION RESULTS
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GROSS PRODUCTION OUTPUT, (pcs)
2014 2015 2016 2017
SPSZ 277 506 554 275 044 504 276 618 654 272 052 827
VSZ 48 115 117 118 883 145 119 776 981 98 270 933
OSZ 268 244 353 186 480 789 158 573 881 231 323 777
KSZ 315 343 381 200 621 055 180 485 776 214 809 395
TOTAL: 844 698 892 875 621 946 951 774 032 878 902 540
PRODUCTION CHARACTERISTICS
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SPSZ KSZ VSZ OSZ
Glass Establishment (Italy) - ZAO "Stekloavtomatika"(Russia)
AMC GLASS (Italy)
Designer of the furnaceequipment Glass Technologies (Italy) Teco Glass (Great Britain) Glass Technologies (Italy) HORN Glass
Industries AG (Germany)
Estimated capacity, ton/day 290 450 220 400Melting area, m2 110 145 80 140
SEPR (France, India)
Start-up year 2014 2012 2014 2010
Linies quantity 5 4 4 5Sections quantity 8 / 6 8 / 10 / 12 6 / 8 8 / 12
Glass-forming machine BDF 5½ , Bottero 6¼ Bottero 6¼ Bottero 5½ BDF 5½
Annealing lehr Antonini (Italy) CAR-MET (Italy)
Control measurement devices
Conveyor lines, palletizer All Glass (Italy) Gemco (Holland),CAR-MET (Italy)
Steklopack (Russia) All Glass (Italy)
Termal shrinking machine MSK (Germany) Emmeti Sipac (USA) Steklopack (Russia) MSK (Germany)
Designer of the dosing andmixing line
StromI (Russia)
KPOK CRRC (China)
Antonini (Italy)
Bush&Spreen (Germany), AGR (USA), IRIS (France), MCAL (France), MULTI (France),M1 (SGCC), FLEXT (Emchart Glass)
Refractory materials
INTEGRATED MANAGEMENT SYSTEM
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Based on the requirements of ISO 9001, ISO 22000, BRC standardsTHE POLICY OF READY PRODUCTS SAFETYAND QUALITY
SAFETY AND QUALITY AIMS FOR THE READYPRODUCTS IN 2018
Management leadership
2nd rule of the Quality Management System:
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INTEGRATED MANAGEMENT SYSTEM
DYNAMICS OF DEVELOPMENT OF THE IMS
89 90
86
92
87
95100
9497
92,992,6
83,4
70,0
75,0
80,0
85,0
90,0
95,0
100,02014201520162017
Suitability Diligence Effectiveness
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INTEGRATED MANAGEMENT SYSTEM
The level of achievementof the quality objectives, %
Customer satisfaction ,index , %
91,6
97,196,9
60
8192
89,1 88,6
0
20
40
60
80
100
120
2008 2010 2012 2013 2014 2015 2016 2017
94,694,3
94,1
92,7
93,5
92,792,2
93
93,8
94,6
2012 2013 2014 2015 2016 2017
PRODUCTS SAFETY
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Safety and quality managementsystem recertificationfor correspondence to therequirements ofthe Global Standard for Packaging andpackaging Materials BRC (v.5)
SPSZ : march 2017
Certificate of conformityPKG40117 of 23.03.2017
Grade achieved A
KSZ: february 2018
Certificate of conformityRU 18/818418679 of 22.03.2018
Grade achieved A
Site BRC:http://www.brcdirectory.com/
INTEGRATED MANAGEMENT SYSTEM
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Integrated safety and quality management system (ISM), meeting theinternational standard BRC requirements, functions at all 4 plants from 2012.
Conformance of ISM at the plants to the BRC requirements is evidenced by periodicthird party audits (external audits).
Positive results of external audits were obtained by the following companies:
- 2014 : NestleKuban - KSZROUST - SPSZ, KSZ, OSZ, VSZ
mskVinProm - VSZ;Aqualife - SPSZ.
- 2015 : Jacobs-Rus - KSZROUST - OSZAqualife, mskVinProm, NestleKuban - SPSZ
- 2016 : SAIGLOBAL - KSZ (certificate BRC, category )Jacobs-Rus - KSZPepsico - SPSZ,KSZAqualife - SPSZ, VSZ
- 2017 : SAIGLOBAL - SPSZ (certificate BRC, category A)- 2018 : SGC - KSZ (certificate BRC, category A)
N o t e:BRC – International standard for packing and packing materials.The standard was first accepted in 2001, published by British Retail Consortium (BRC)for consumer protection
PRODUCTS
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The glass factory produce more than 300 types of flint glassware for:
baby food products,distilled beverages, cognacs and liqueurs, vines and drinks,beer, fizzy drinks, mineral water,low-alcohol beverages and soft drinks,preserved fruit and vegetable products,coffee and coffee products,milk and milk products,fish products.
Glassware made at the glass factories isnotable for the high European quality,it is ecologically clean,it has a high water and chemical resistance,it is durable and light, its geometry is ideal,And it differs for the exclusive design.
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Constant improvement
6th rule of the Quality Management System:
PRODUCTION DEVELOPMENT
2014 – SPSZ2016 – OSZThe COLOURED container’s glass is madefor the food and perfumery-cosmetic productionaccording to GOST 52022
Glass COLOURING is made by adding glass frittto the feeder chanel (on one machine-line)
Mass concentration of glass fritt(Co, Mn) is from 0,05 to 3 %
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2016 –Introductionof medical products production
Glass bottles for blood, transfusion and infusionpreparations, capacity 250 and 450 cm3
PRODUCTION DEVELOPMENT
OUR CUSTOMERS
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Baby food:«Progress», «Sadyi Pridonya»
Coffee:«Mondelez», «Nestle»,«Megapolis»(Sara Lee), «Center Snub»
Vodka:«ROUST» (CEDC),CJSC Yerevan Brendy Company (Pernod Ricard),«Rospischesnab»«OmskVinProm», «Russkiy Sever»
Juices,Preserved food:«Multon» (Coca-Cola),«Selizharovsky canning factory »«Baltimor»
CONFORMITY OF GOODS
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UNITARY STANDARDfor the output products
DECLARATIONof the products conformity to the
requirementsof the Technical regulations
«Packaging safety»
PRODUCTS SAMPLES’ TESTSin the accredited laboratories (of the Customs Union)
SAFETY MANAGEMENT
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BIOLOGICALCHEMICALPHYSICAL
HAZARDRISKS'DETECTIONAND ANALYSIS
HACCP PLANCRITICAL CONTROL POINTMONITORING
MAIN WORK DIRECTIONS :• implemetation of HACCP
• documenting and increasing of Quality systemeffectiveness
• production environment, personnel, products,processes and ecological aspects control
• production standards, products and personnel control
Current control and constant quality,hygiene and product safety improvement
PRODUCTION AREA
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Batch house Furnace Hot end Cold end Warehouse
Process approach
4th rule of the QMS:
System approach to management
5th rule of the Quality Management System:
1. Batch preparation2. Batch and cullet supply into the
furnace3. Glass melting4. Glass mass preparation for forming5. Glassware molding
6. Hot end coating application7. Annealing8. Cold end protective coating
application9. Glassware quality inspection10. Packaging11. Glassware delivery to the customer
BATCH HOUSE
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Mutually beneficial cooperation with thesuppliers
8th rule of the Quality Management System:
GLASS-MELTING FURNACE
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GLASS-MELTING FURNACE EQUIPMENT
CENTRAL FACTORY LABORATORY
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• Raw materials incoming inspection
• Chemical composition analysis ofglass, raw and auxiliary materials
• Products water and acid resistancetests
X-ray fluorescence wave-dispersive spectrometerS4 PIONEER
• Chemical composition analysis• Elements’ analysis• Tested concentrations range is from ppm to %
GLASS-FORMING MACHINES
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6 sections8 sections
10 sections12 sections
DOUBLE GOB glass-forming machines BDF,Bottero
QUALITY CONTROL AT THE HOT END
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Glass machine operator
Controlled parameter Method Cycle
1.Visual defects Visual inspection
EVERY HOUR –1 sample
from each form2. Geometricaldimensions
Gauge – CORKGauge - CLAMP
Vernier height gauge
3. Weight, g Automatic scales
Products thermogramanalysis after formingprocess
ANNEALING QUALITY CONTROL
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Polariscope-polarimeter -250
ANTONINI ANNEALING LEHR
Residual strength levelcontrol
PROTECTIVE –FORTIFYING COATINGS
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AGR equipmentHot-end coatingcontrol
Cold-end coating
COLD END
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CONSTANT VISUAL INSPECTION
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The samples of glassware faults detected at the viewingscreen inspection:
CCP-1
Register « onitoring CCP-1»every 30 min
TECHNICAL QUALITY INSPECTION
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LINE INSPECTION PLAN
Controlled parameter Method Cycle
1.Visual defects Visual inspection EVERY 2 hours
2. Geometrical dimensions
Gauge - CORKGauge - CLAMP
EVERY 2 hours
Height gauge,Thicknes gauge,probes,line gauge
ONCE PER SHIFT
THE LIST OF CONTROLLEDPARAMETERS
WORKING AREA OF QUALITY INSPECTION CONTROLLER
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Inspection tools:
FAULTS SAMPLES FOR THE INSPECTIONEQUIPMENT ADJUSTMENT
PHYSICAL LABORATORY OF QUALITY INSPECTION
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PHYSICAL PARAMETERS CHECK
DATA STATISTIC ANALYSIS
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1,51,8
1,51,2
3,8
2,5
4,8
4,2
0
1
2
3
4
5
6
7
,
Take decisionsbased on facts
7TH rule of QMS:
GLASSWARE FAULTS CLASSIFIERPARETO DIAGRAM, GRAPHS
AUTOMATED QUALITY INSPECTION
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MCAL INSPECTION (FRANCE)
- critical faults: glass birdcage, glass stick- visual body faults: foreign inclusions, bubbles, tears- geometrical dimensions: diameter, height, perpendicularity- quality of annealing
Main test parameters:
AUTOMATED QUALITY INSPECTION
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MULTI INSPECTION (GERMANY)
- critical faults: glass birdcage, glass stickvisual bottom faults: tears, foreign inclusions, bubbles…
- visual finish faults (from 40 mm);- mould code reader (alfa-code, dot-code, LMNC)
Main test parameters:
AUTOMATED QUALITY INSPECTION
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SGCC inspection M1
- finish inner diameter- wall thickness- top of the finish planeness- checks
Main test parameters:
AUTOMATED QUALITY INSPECTION
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EMHART GLASS inspection
Main test parameters:
- visual body faults: foreign inclusions,bubbles, tears- geometrical dimensions: diameter,height, perpendicularity- quality of annealing
PRODUCTS SAFETY
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SPECIAL CONTROL:Baby food and coffee
POLLUTION AND INGESTION CONTROL
OBLIGATORY RUN-UP (GMP, PRP)
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EXTERNAL VIEW REQUIREMENTS :
PROHIBITED: ALLOWED:
SANITATION LOG:
PALLETIZING
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CCP-2
Registeronitoring CCP-2» -
every 3 hours
THERMAL SHRINKING MACHINE
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AUXILIARY MATERIALS
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FINISHED PRODUCT STORAGE
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Condition 2: covered unheated warehouseCondition 5: shelterCOndition 9: open platform
DISPATCH
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QUALITY PASSPORT
CONSUMER'S LABEL
CCP-4 DISPATCH REQUIREMENTS
CUSTOMER’S SATISFACTION
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• Returns level• Proportion of the products accepted with comments• Defects level in the defects’ groups
MEASURED VALUES:
• Problems analysis• Complaints reasons’ analysis• Corrective actions
ADMINISTRATION:
HOW OFTEN THE DATA IS TO BE PROVIDED - ONCE A MONTH
PRODUCTS RETURN LEVEL IN 2016-2017
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0,06 0,10
0,80
0,03
0,31
0,01 00,0
0,5
1,0
20162017
Glass factories supplyingthe products of LLC «TC «RUS-STEKLO»
RETURNS LEVEL DIAGRAM
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Information from:LLC "SERGIEV-POSAD GLASS FACTORY" during 2016 - 2017
0,270
0,700,53
0,48
0,25
0,280,280,280,27
00
0,55
0
0,5
1
1,5
2
"0" 1 2 3 4 5 6 7 8 9 10 11 12
CONSUMERS’ CLAIMS
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Information from: LLC «Sergiev-Posad Glass factory»
THE BATCHES PARTLY RECEIVED WITHCLAIMS
LEVEL DIAGRAM
FAULTS LEVEL IN THE FAULTS' GROUPS
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Information from:LLC "SERGIEV-POSAD GLASS FACTORY" during 2017
FAILTS LEVEL (ppm)
A2 - criticcal 3 – criticcal - dangerous
COMPLAINTS REASONS’ ANALYSIS
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Customer orientation1st rule of QMS:
Personnelinvolvement
3rd rule of QMS:
Constant improvement
6th rule of QMS:
CLAIM CONTROL CARD
RETURNS ANALYSISRETURNS ANALYSIS
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Information from:LLC "SERGIEV-POSAD GLASS FACTORY" during 2017
4
1 1 1
21 1 1 1
100
46
54
6269
7785
93
0
1
2
3
4
5
0
20
40
60
80
100
120%
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ThankThank youyouforfor youryour attentionattention!!