EMPOWERED

OPERATORS

Şahin Keykan

CCI Ankara Plant Manager

Share Best Practice Conference

Dubai

September 29, 2013

The Coca-Cola Company

CEO of TCCC- Muhtar

Kent

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

Operating Geography

Shareholder Structure

• 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

Excellence Journey for Ankara Plant

• 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

• Operates the machine perfectly

An Empowered Operator

A labeling operator working at his station

• 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

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BURHAN ÇINAR

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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

Thank You…