Behind the Scenes

TQC Winner 2009

Behind the Scenes

TQC
Winner
2009

/









1

ISBN

12-15
1025
10400
0-2619-5500 630, 631, 632, 633, 636,
0-2619-8086
0-2619-8085
www.tqa.or.th
tqa@ftpi.or.th
2554
3,000
978-616-7148-88-5

4
Behind the Scenes
TQC Winner 2009
()
7



()
27
/



45
()



67

Behind the Scenes

TQC Winner 2009

.. 2552 (Thailand Quality Class : TQC)
3 ()
()
()

3



3

()
(Bangkok Produce Merchandising
Public Company Limited)

Behind the Scenes

TQC Winner 2009

Behind the Scenes

TQC Winner 2009


() Bangkok Produce Merchandising


Public Company Limited BKP
()
98 () CPF

(CPG) CPF

2 (1) (2)





2 3 (Feed)

(Farm) (Food)

BKP .. 2522
.. 2530

600 .. 2532
(Slaughter Plant) 150 150 7

.. 2533
Further
.. 2537

Behind the Scenes

TQC Winner 2009

.. 2541
()
Further 2 .. 2544 BKP



.. 2547


BKP Slaughter House

Further BKP

BKP Further 3 .. 2549

BKP OEM 93%
BKP CP
Brand 7% .. 2551 CPF CP Brand

280,000

(Halal)

100,000 77%



30,000 23%


BKP
1. (CPF Trading Co.,Ltd.
CPFT) Primary Customer

75% ( 40%)
2. .. (C.P. Merchandising
Co.,Ltd. CPM) Primary Customer

24% 1% ( 60%)

BKP Main Product

By-Product



3

CPF



Kitchen of the World BKP
CPF

(Vision) : BKP
CPF

(Purpose) :


(Mission) :


(HESTSEC : Healthy, Education, Safety,
Tasty, Security, Environment, Customer & Market Focus)

BKP

6 CPF Way 

()


CPF Way 6


1. (Embrace Change)

2. (Master Learning & Sharing)

3. (Innovation)

4. (Integrity & Honesty)

5. (Result Oriented)

6. (Dedicate to Countries)

10

Behind the Scenes

TQC Winner 2009

20 BKP




ISO 9001 .. 2540

HACCP

.. 2541
ISO/IEC 17025
.. 2547




ISO 14001 ..
2543


.. 2550
Thailand Energy Awards
.. 2551
Thailand Esco Project Award 2008




OHSAS 18001 .. 2545

7 ( .. 2546 - 2552)
CP 8

( .. 2538 - 2552)

.. 2548



(Animal Welfare)
.. 2547

British Retail Consortium Standard : BRC

.. 2546
Supplier of the Year 2007 : KFC UKI
Outstanding Commitment to Animal Welfare (Best Overall Animal
Welfare Audit Performance 2007 : KFC UKI )

(. 8001) ..
2548

1 BKP

..

u
2542

2543

ut
2544

2545


utl
2546

2547 tl

uln
2548

l
2549

ull
2550

tllll66
2551

tllll666
2552


u t l 6 n



BKP

80 (CPG)
CPF BKP

BKP 2

11

()

12

Behind the Scenes

TQC Winner 2009

.. 2516
2 BKP


BKP



:




1. BKP
.


30
2. 5,000
2 140

.
3. BKP


4.


5.

BKP



Low Care High Care Low Care
High Care









100%

1 1

Flow

One Way System -


Lay-out


- 13

()

One Way System













1 Lay-out BKP

14

Behind the Scenes

TQC Winner 2009

BKP

Real-time


Water-Chilled Slaughter House
IQF Further
400

BKP

BKP

BKP

Co-Generation 30-40

Biodiesel
Biodiesel Green Energy





BKP

ISO 9002 .. 2538 BKP


BKP


BKP
BKP




(Basic Requirement)

BKP Good Manufacturing Practices (GMP)

Hazard Analysis and Critical Control Point (HACCP)

 EST/TH, ISO 9001

BKP



British Retail
Consortium Standard (BRC)
Islamic Approval of Muslim Religious
Food (Halal) Assured Chicken
Production (ACP), Testing Laboratories (ISO/IEC 17025)

BKP OSHAS 18001 (Occupational Safety

& Health Administration Management System)

ISO 14001

TLS 8001 (Thai Labour Standard)


BKP

15

()








CPF

BKP

BKP

16

Behind the Scenes

TQC Winner 2009

BKP Quality System

BKP Fully
Integration Feed Farm
Processing
Food Ready Meal


PDCA :

BKP
PDCA-BKI (Plan-Do-Check-Act-Benchmarking-Kaizen-Innovation)
(Daily Management)

PDCA

(Weekly Benchmarking/Kaizen/Innovation)

(Benchmarking) 3 CPF

(Continuously Improvement)

Kaizen-DMAIC (Kaizen-Define-Measure-Analyze-Improve-Control)
(Innovation)





1.

Incentive



Spec (

) Rework
Rework


BKP BKPCompetition
Ingredient

2. Work
Instruction (Incentive)

Incentive Incentive


3. ( GM, DM)

Auditor Monitoring

ISO, SHE























2 PDCA-BKI

17

()

18

Behind the Scenes

TQC Winner 2009

Kaizen Innovation


PDCA-BKI
BKP
1 CPF-INNOVACO
BKP
(KM-Focus)

INNOVACO

Quality Control Cycle (QCC)
INNOVACO

INNO = Innovation

V = Valuable

A = Applicable

C = Creative

O = Organization Learning & Teaching




BKP
BKP-Innovation Senior Leader Team (SLT)

2 Innovation Scoring and Reward INNOVACO
Inno-
V-Valuable

0-25%
1

A-Applicable

(Copy &
Development)
O-Organizational

Learning &

Teaching
KM

C-Creative

26-50%
1
5

51-75%
5
10

(Create
& Development)

KM

OL

76-100%
10

OL OT

CPF

 3 BKP-Innovation

Lean Six Sigma

INNOVACO


BKP Lean
Six Sigma

(Cumulate Monthly)

4 Lean/Six Sigma

19

()

20

Behind the Scenes

TQC Winner 2009

BKP
5,000 CPF

80 CPF CPF Way

BKP
2 1 ( )
BKP

CPF Way
1.
BKP


15



2. BKP

3. BKP
INNOVACO Day

Why-Why Analysis,
Kaizen, Lean Six Sigma

4. BKP

5. 2
1
Follow Up Coaching
BKP

BKP
(HESTSEC)
6. BKP



.
. . .

-
. .

BKP

Core Competency

BKP Core Competency


(Schooling, Mentoring,
Coaching)

(LCA : Leadership Competency Attitude)
BKP

2
1. (GDP)
Employee Champion Development
Productivity Manager Development

21

()

22

Behind the Scenes

TQC Winner 2009

2. (OJT)


Schooling, Mentoring, Coaching

Level 4
GM/
AVP/VP
Level 3

DM
Level 2


SM
Level 1

(Staff)

5 Training GDP Roadmap

6 OJT


BKP (Career Progression)


Talent Management

Succession Planning System

(Talent & Succession) Fast
Track (IDP)

(Lean & Six Sigma)


CPF

BKP

23

()
6

BKP
BKP

TQA

.. 2551 BKP


BKP

BKP

24

Behind the Scenes

TQC Winner 2009

CPF (Assessment)




BKP


BKP BKP





TQA BKP
Application
(Support Team) Application


TQA





TQA

BKP
Cross Functional Team


TQA




Morning Talk


BKP


TQA
BKP

(TQC) .. 2552

()
(Thai Oil Public Company Limited)

25

()

26

Behind the Scenes

TQC Winner 2009


Rome not built in a day. The Road to Success is always under
27
construction.

()
()




50
Operation Excellence

(Complex Refinery)






(TQA)
3

(High Performance Organization : HPO)

(Good Corporate Governance)
(Corporate Social Responsibility : CSR)
(Thailand Quality Class : TQC) .. 2552

28

Behind the Scenes

TQC Winner 2009

.. 2504

20

Build Own Transfer (BOT)

()

() .
3

60%

.. 2535 2 RRC
SPRC 35,000

180,000



.. 2538 - 2539 ISO



ISO By Product
ISO 9002 (
ISO 9001)



(ISO/IEC Guide 25 ISO/IEC 17025)

(ISO 14001)

(. 18001) 3 ISO 9001,

ISO 14001, . 18001 3
(.)
IMS (Integrated Management System)

29

()
(BS-OHSAS
18001)

QSHE & CSR Policy QSHE
Quality, Safety, Occupational Health Environment QSHE &
CSR Policy PRAISE Prevention / Risk /
Awareness / Improvement / System / Employee
PRAISE

1 PRAISE

30

Behind the Scenes

TQC Winner 2009

2548 Shell Global Solutions

International

SET Awards 2005 Best Newly Listed Company



(Energy Awards)
.. 2548


2549 1 13 FORBES GLOBAL
2000 .. 2549

(SMPCS = Shell Main Product
Correlation Scheme) SGS (Shell Global Solution)
Lab (Unknown Sample)
SGS 150

Platts TOP 250 Global Energy Companies Awards
Platts Top Companies in
Asia 33 140

 2550 Platts TOP 250 Global Energy Companies Awards

Platts Top Companies in
Asia 35 154
Platts TOP 250 Global Energy Companies Fastest - Growing Companies
in Asia 17

(Good Laboratory

Practice / Department of Industrial Works (GLP / DIW)

2551 Thailand Energy Awards 2008


ASEAN Energy Awards 2008 Energy Management in
Industry .. 2551

Best CEO Awards 2008

2552 (Board of the Year Awards) ..
2551 / 2552
31


()
(Integrated Management System : IMS)
(.)

EIA Monitoring Awards 2009

.. 2552


2553 1 10 (Best Managed
Company) Finance Asia


(Most Committed to a Strong Dividend Policy) 11

Finance Asia

(Thailand Quality Class : TQC)

TOP Corporate Governance Report Awards

32

Behind the Scenes

TQC Winner 2009

MQOC MQOC
Consultant Tool Provider Task Force
Implement (Implementation Planning)

MQOC











2

MQOC

IFP ISO Focal Point Internal

Auditor 2 Task Force

(Recognition)
MQOC



1-2 2 6

 Work Instruction

Task Force Work Instruction Procedure


Implement

QSHE Roadshow Event

QSHE Award OFI Champion / Internal Audit

Champion / IFP Champion

MQOC

1-3

Task Force IFP (ISO Focal Point)

2

33

()

34

Behind the Scenes

TQC Winner 2009

4-5 System Requirement Training

System Requirement, Document Control Writing,






6-8
Internal Audit Internal Audit

Management Review


9 Application .
. National
Certified Body




Internal Audit, Management

Review External Auditor
Internal Audit External Audit

.. 2540







.. 2547

By Product

2

High Performance (Competency)


(Engagement)





(Corporate Social Responsibility)

35


()

20




(Good Governance)








TQA
TQA .. 2551
TQA .. 2552
TQC

36

Behind the Scenes

TQC Winner 2009

TQA
TQA

TQA
(TQA Application Report)

TQA
(Application
Report)


Application Report

TQA





1. POSITIVE

POSITIVE
(Professionalism)



(Ownership & Commitment)

 (Social Responsibility)

(Integrity)

(Teamwork & Collaboration)

(Initiative)


(Vision Focus)

(Excellence Striving)


37

2. 5F
5 Fast, Focus, Friendly, Flexible Fair
()



(Key Focus Area : KFA)
12

Operation Excellence
Workshop


TQA

TQA



(Learning)


TQA







()

38

Behind the Scenes

TQC Winner 2009

Implement

Management Meeting











(Ownership)

()
(Pak Thong Chai Feedmill, Charoen Pokphand Foods
Public Company Limited)

39

40

Behind the Scenes

TQC Winner 2009


() CPF
(CPG)
41

CPF
CPF

CPF (CPF
Value Chain)

1 CPF Value Chain

42

Behind the Scenes

TQC Winner 2009

CPF .. 2506


CPF 11


(Pak Thong Chai Feedmill : PTF)
11 .. 2547



(PTF)
CPF

PTF

1.2 (Bulk)

(Bag)

2

1. ()





2. One Stop Service

(Kitchen of the World) CPF




PTF CPF
CPF Way















CPF Way

1.
2.
3.

4.
5.
(Embrace Change)
(Master Learning & Sharing )
(Innovation)
(Integrity & Honesty)
(Result Oriented)
(Dedicate to Countries)

.. 2547


(Excellence in Construction Award :

Eagle Award)
.. 2548 - ISO 9001
.. 2548 - GMP & HACCP
.. 2552
Thailand Quality Class

(TQC)

.. 2550
5 Thailand 5S Award
.. 2551
OEE (Operational Efficiency and Effectiveness)

Award
.. 2551
Kaizen Award
.. 2552
Feed Innovation CEO Award

43

44

Behind the Scenes

TQC Winner 2009

.. 2549 -




.. 2551



(Thailands Prime Minister Industry Award)

.. 2551
Zero Accident

.. 2553
Zero Accident


(.-)




.. 2547 -


ISO 14001

.. 2549


.. 2549


.. 2553
Thailand Energy Award 2010


ASEAN Energy Award 2010 :


Special Submission





(Thailands Prime Minister Industry Award)

(PTF) 11

() CPF PTF



9

(Food Safety) (Core Competency)




PTF


PTF 50
PTF






10
PTF (Plant Layout and Plant Design)
GMP
HACCP, European Feed Manufacturers Federation Guide /
/
100%




PTF SLIP FORM 45

Food Safety



PTF
Excellence in Construction Award (Eagle Award)

2 SLIP FORM

46

Behind the Scenes

TQC Winner 2009

PTF (Plant Control
System) Real-time
PTF


CPF

PTF

PTF



Leadership Development Course

(Training Roadmap)



Manager Development

Global
For Management Level : VP AVP GM

Advisor Development

People
For Department Manager



Productivity
Manager Development
For Supervisor



CPF Ambassador

For Employee

2
1

3 Leadership Development Course



PTF

PTF
Organizational Development for Sustainability PTF
Road Map .. 2004

PTF


PTF
(Benchmarking)

(Core Competency) PDCA






47

4 PTF Road Map

5S Program Safety Policy

PTF 5

.. 2004

5


CPF 5

11 Best Practice 5
CPF

 : %

5 PTF

5

Machine Breakdown


6




4


2


0

2548
2549
2550
2551
2552
PTF
XXX
Target

5 Breakdown

48

Behind the Scenes

TQC Winner 2009

2 Quality Policy, Food Safety

PTF Quality Policy,

Food Safety ISO 9001, GMP & HACCP ISO 9001

PDCA

GMP & HACCP




3 SHE Policy, EMP, KM, Energy Saving Program

PTF SHE-Safety Health Environment Environmental
Management Plan (EMP) 5
ISO 14000

PTF

: %

2548

2549

2550
PTF

2551
Target

2552

PTF


PTF
(Cover) Sensor


(Explosion Proof)

PTF

(Personal Protection Equipment
: PPE)
Safety Morning Talk
KYT (Kiken Yoshi Training)



(Safety Audit)

4
(Behavior Based Safety)

()

49

50

Behind the Scenes

TQC Winner 2009

.. 2551 PTF
(Thailands Prime Minister Industry
Award)

PTF (Energy Saving Program)
(Small Group Activity : SGA)




SGA


















7

PTF 10

(Knowledge Management : KM)













8 Web KM

4 IT Security, 5S VFP

PTF
IT Hardware Software
51

PTF ISO 27001 (IT Security)

IT PTF
IT

ISO 17799

5 5S VFP VFP Visual
Feedback Photography 5 -




5 Kaizen, Lean

PTF Kaizen
Suggestion - Kaizen
Suggestion


Kaizen Suggestion
(Creative Thinking)

52

Behind the Scenes

TQC Winner 2009

(Wastes)
Small Group Activity

Kaizen Suggestion




Kaizen













9
Lot.No




1.

2.

3.



1.

2.

3.


1-2 1 (1 5 )





(1 6 )

1










1.


2.


3.

53

54

Behind the Scenes

TQC Winner 2009

2 600












3







1.


2.


3.










(1 )

6

5


21


Kaizen Innovation

CPF 11 Feed
Innovation CEO Award PTF Kaizen Suggestion

Feed
Innovation CEO Award 3












Feed Innovation CEO Award



Feed Innovation CEO Award

Power Peak

PTF
TOU (Time of Use Rate) PTF Power Peak

55





Power
Peak

(Simulation)

56

Behind the Scenes

TQC Winner 2009


Power Peak Innovation

PTF


Lean

Lean PTF

7



7 (7 Wastes) ...


1. (Unnecessary Motion)


2. (Idle Time/Delay)


3. (Non-effective Process)

4. / (Defects/Reworks)


5. (Overproduction/Overprocessing)


6. (Unnecessary Stock)


7. (Transportation)




Lean
57

Lean PTF 7

1.

2.

3.

4. /

5.

6.

7.


Lean




Oil Cooler

58

Behind the Scenes

TQC Winner 2009

56 37

59

60

Behind the Scenes

TQC Winner 2009

19

55,335


Lean PTF 7

 (Productivity Improvement)


PTF

.. 2551

7

(OFI : Opportunity for
Improvement) PTF




PTF

(Application Report)

7 61

(Cross Functional Team)

(IT System )




Top Management Review Management Review,
VDO Conference, 5 Minutes
Talk 5 Kaizen Lean


PDCA

62

Behind the Scenes

TQC Winner 2009

(Total Success Solution)


CPF Value
Chain


PTF

CPF

PTF
(TQA)

PTF

(CPF)



PTF




PTF


.. 2547 .. 2552 PTF
(Thailand Quality Class :
TQC)

()
1.


2.


3.


4.


5.


6.


7.

8.


9. ..

10.

11.


12.


13.


14.


15.

16.


17.


18.

19.


20.


21.


22.

23.

24.

25.

26.

/
27.


28.

29.

30.

31.


32.


33.


34.

35.


36.

37.



()
1.

2.


3.


4.


5.

-
6.


7.


8.

-


()
1.


2.


3.


4.


5.


6.


7.


8.

1
9.


10.

11.


12.


13.


14.

15.


16.


17.


18.

1
19.


20.



.

 () ....................................................................................
.........................................................................................................

1.
o
o
2.
o o
3.

4.

o 20
o 21 - 30
o 31 - 40
o 41 - 50
o 60
o 20,000
o 20,000 - 50,000 o 50,000 - 100,000
o 100,000 - 150,000 o 150,000

1.
2.



3.

o o o
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.........................................................................................................................................
.........................................................................................................................................
/ TQA ...............................................................................
.........................................................................................................................................
-
()
- ........................................................ ....................................................
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................................. .................................... E-mail ...............................

0-2619-8085
12 - 15 1025 10400

20


43/2549
.

15 1025
10400