Saving Template 2013

VIETNAM BREWERY LTD.
PLANT : TIEN GIANG
SAVING CALCULATION SYSTEM

Quality
Organization
& People
development
Social Responsibility
Customer satisfaction
@ Version 01 - Jun2011
IEN GIANG
Prepared by : Tran Thanh Tuan - TPMC VBLH
EXTRACT LOSS
ONE WAY PKG MATERIAL
Productivity &
Cost leadership
r satisfaction
GTF
OPI
ELECTRICITY
WATER
THERMAL
PRODUCTIVITY
Tran Thanh Tuan - TPMC VBLHCM
EXTRACT LOSS
ONE WAY PKG MATERIAL
OPI
ELECTRICITY
WATER
THERMAL
PRODUCTIVITY
PLANT :
ONE WAY MATERIAL LOSS SAVING

FY :
2012/2013
FORMULAS
Starting point :
Target :
Actual :
Volume can produced target :
Volume can produced actual :
Empty can price budget :
Empty can price actual :
a
b
c
V1
V2
P1
P2
%
%
%
Hl
Hl
VND/pcs
Input data
BUDGET FIGURES
Input data
Start FY date :
End FY date :
1-Jan-13
31-Dec-13
Volume can produced target:

Empty can price :
Last year achieved :
FY target :
Exchange rate:
1USD =
531,752
1,386
0.46
0.36
SAVING CALCULATION
Project saving contribution into FY calculation
Project closed date :
Starting point:
23-Jul-13
dd/mm/yy
159,309 can
21,220
Target:
Actual :
59,741 can
59,741 can
# of month the project contributes to full FY

# of month the project contributes to YTD
5.37 month
36.70 month
Full FY Saving
x1000'VND
USD
PLANNED SAVING
246,831
11,632
ACTUAL SAVING
231,550
10,912
YTD Saving
x1000'VND
USD
PLANNED SAVING
1,687,956
79,546
ACTUAL SAVING
1,583,460
74,621
24,399.28
After upgrating new ECI can rejection go up to over 0.4% due to sensitive setting too tight
and too many dented can due to transportation
- Reduce can rejection at ECI from 0.4% to under 0.15%
V.B.L PACKAGIN
Canning Line
Type of beer
Tiger Beer
Type of Packaging
Tiger - Can 330ml - Carton
BOTTLES/CAN ACCOUNT
Pallets
Bottles/Cans received at depalletiser
Bottles/ Cans cases returned
Bottles/Cans received by production

Reject/Samples
Counter inlet can depalletizer
0.18%
ECI total rej
73,636
Difference from Depalletizer to filler
Dirty (conv. #1) rejects
0 Counter inlet ECI
Return to bot. Washer
Loss from ECI to filler (not in clude ECI rejects)
Dirty return to empty store
585 Counter inlet Filler
Rejects account
585 Counter outlet Filler (FHI good prod)
Breakages Filler
Rejects by
0.02%
FHI No 1
FHI No 2
Total rejects b
Rejects by
Difference from Filler to FHI (+Lab)
772 Counter FHI No.1 (good prod.)
0.03%
772 Counter FHI No.2 (good prod.)
Taptone No 1
0 Total good prod. By both of F.H.Is
Taptone No 2
Difference FHI to Palletizer
Total rejects by Taptones

Total Quality Rejects: [C]=
Total samples t
0.03%
0 Good Products
1,357
625
Total can loss (Inlet-Outlet)

Total Breakage on line
TIEN GIANG
Prepared by : Tran Tha
ING
HOME
* YTD Saving ( to be used for saving of gap to be filled calculation )

PLANNED SAVING
[x1000'VND]
ACTUAL SAVING
[x1000'VND]
Calculated data
dd/mm/yy
dd/mm/yy
Hl
Auto updated data

Volume can produce YTD :
Can loss YTD :
FY ran over :
Empty can price :
446,411
0.55
43.0
1,300
VND/pcs
%
Volume can produced foreseen :
124,580
%
VND
KPI - Full FY
Saving (calculated data)
x1000'VND
USD
PLANNED SAVING
223,302
10,523
FORESEEN SAVING
(44,169)
(2,081
KPI - YTD Saving contribution (Calculated data)
x1000'VND
800,166
37,708
(158,273)
(7,459
PLANNED SAVING
ACTUAL SAVING
USD
setting too tight
PERFORMANCE REPORT week
DAILY
Shift
Week No
Line
0
Layer
Pcs
A0
Date
Number
Breakages
2,387,880
0.015%
366
A
2,387,514
2,387,514
3,698
0.155%
0.000%
460
0.019%
165
0.007%
-5,083
-0.21%
2,383,816
39,827,128
2,382,771
2,381,669
0
2,381,669
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
99,448
2,386,752
../B
1,128
0.05%
../B
137
0.01%
repared by : Tran Thanh Tuan - TPMC VBLHCM
[x1000'VND]
[x1000'VND]
446,411 Hl
0.55
43.0
month
1,300 VND/pcs
124,580 Hl
culated data)
10,523
(2,081)
(Calculated data)
37,708
(7,459)
11,219
5,151
2,668
3,841
1,609
6,184
4,631
2,614
5,913
5,659
1,807
2,414
1,484
2,125
8,932
5,959
4,777
3,340
2,476,659
2,880,815
886,355
2,241,600
398,800
3,057,669
2,176,396
905,300
3,212,735
3,010,948
1,128,090
2,755,954
1,913,366
1,939,750
3,268,879
4,017,115
3,422,000
4,175,806
PLANT :
EXTRACT LOSS SAVING CALCULATION

FY :
2012/2013
FORMULAS
Starting point :
Target :
Actual :
Volume produced target :
Volume produced actual :
Brewing var cost budget:
Brewing var cost YTD:
a
b
c
V1
V2
P1
P2
%
%
%
Hl
Hl
VND/Hl
VND/Hl
Input data
BUDGET FIGURES
Input data
Start FY date :
End FY date :
1-Jan-13
31-Dec-13
Volume Tiger produced target:

Tiger brewing var budget :
FY target :
Exchange rate:
1USD =
SAVING CALCULATION
Project saving contribution into FY
Starting point:
19-Feb-13
-
dd/mm/yy
hl
352,768
236,405
6.38
5.13
21,220
Target:
Actual :
2,610 hl
2,610 hl

10.50 month
41.83 month
Full FY saving
x1000'VND
USD
PLANNED SAVING
2,159,560
101,770
ACTUAL SAVING
2,027,066
95,526
YTD Saving
x1000'VND
USD
PLANNED SAVING
8,603,960
405,465
ACTUAL SAVING
8,076,087
380,588
109,173
PQ25(Tiger)
Parameter Value
Production v
286,775
Extract of 1hL
11
Total extract
3,257,764
% brewery los
0.91
Equivalent to
29,646
Equivalent to
2,610
2,316,646
Unit
hL
kg
kg
kg
hL
TIEN GIANG
LATION
HOME
SAVING CALCULATION
PLANNED SAVING
[x1000'VND]
ACTUAL SAVING
[x1000'VND]
Calculated data
dd/mm/yy
dd/mm/yy
Hl
Auto updated data

Volume produce YTD
extract loss YTD :
FY ran over :
Brewing var YTD :
229,075
6.53
43.0
221,901
VND/Hl
%
Volume produced foreseen :
%
VND
KPI - Full FY Saving (calculated data)
63,928
x1000'VND
PLANNED SAVING
FORESEEN SAVING
USD
1,042,451
49,126
(21,278)
(1,003)
x1000'VND
PLANNED SAVING
ACTUAL SAVING
3,735,451
(76,248)
USD
176,034
(3,593)
[x1000'VND]
[x1000'VND]
229,075 Hl
6.53
43.0
month
ted data)
221,901 VND/Hl
63,928 Hl
49,126
(1,003)
lculated data)
176,034
(3,593)
PLANT :

FY :
2012/2013
FORMULAS
Starting point :
Target :
Actual :
a
b
c
V1
V2
P1
P2
%
%
%
Hl
Hl
VND/Hl
VND/Hl
Input data
BUDGET FIGURES
Input data
Start FY date :
End FY date :
1-Jan-13
31-Dec-13
Volume produced target:

Brewing var budget :
FY target :
Exchange rate:
1USD =
SAVING CALCULATION
Starting point:
17-Sep-13
dd/mm/yy
0.0000095 hl
701,164
230,000
5.27
5.13
21,220
Target:
Actual :
0.0000030 hl
0.0000030 hl

3.50 month
34.83 month
Full FY saving
x1000'VND
USD
PLANNED SAVING
305.74
14.41
ACTUAL SAVING
291.58
13.74
YTD Saving
x1000'VND
USD
PLANNED SAVING
3,042.81
143.39
ACTUAL SAVING
2,901.94
136.75
47.11174445
From April 2013 to Jul 2013 beer loss due to overfilled go up to 0.08% (target 0.05%)
Due to:
Volume content average per can 330.35 ml (V_ave)
And high variation of filling content: Stdev 2.65
Result in:
Loss beer = V_ave - Q_r = 330.35 - 329.4 = 0.95 ml per can
Or V_ave = Q_r + 0.95 ml
In there:
Volume requirement (Q_r) = 330 - 0.234*Stdev = 330 - 0.234*2.65= 329.4 ml (Q_r)
Target setting (SMART):
- Reduce beer loss due to overfilled by to be monitored 02 conditions:

+ Qrequirement <= Actual volume content average on 03 rounds of filler <= Qrequirem
(Qrequirement = 330 - 0.234*Stdev)
+ Stdev from 03 rounds of filler <= 1.1
reduce loss :0.65 ml (from 0.95 to 0.3ml)
TIEN GIANG
ATION
HOME
SAVING CALCULATION
PLANNED SAVING
= (a-b)/100*V1*P1/1000)
[x1000'VND]
ACTUAL SAVING
= (a-c)/100*V2*P2/1000
[x1000'VND]
Calculated data
dd/mm/yy
dd/mm/yy
Hl
Auto updated data

Volume produce YTD
extract loss YTD :
FY ran over :
Brewing var YTD :
495,866
5.06
43.0
219,352
VND/Hl
%
%
VND
138,381
x1000'VND
PLANNED SAVING
USD
225,775
10,640
63,744
3,004
FORESEEN SAVING
x1000'VND
USD
PLANNED SAVING
809,028
38,126
ACTUAL SAVING
228,415
10,764
nds of filler <= Qrequirement + 0.3ml
[x1000'VND]
[x1000'VND]
495,866 Hl
5.06
43.0
month
ted data)
219,352 VND/Hl
138,381 Hl
10,640
3,004
lculated data)
38,126
10,764
PLANT :

FY :
2012/2013
FORMULAS
Starting point :
Target :
Actual :
a
b
c
V1
V2
P1
P2
%
%
%
Hl
Hl
VND/Hl
VND/Hl
Input data
BUDGET FIGURES
Input data
Start FY date :
End FY date :
1-Jan-13
31-Dec-13
Volume Bivina produced target:

Bivina brewing var budget :
FY target :
Exchange rate:
1USD =
SAVING CALCULATION
Starting point:
27-May-13
-
dd/mm/yy
hl
159,830
234,272
6.47
5.13
21,220
Target:
Actual :
765 hl
765 hl

7.27 month
38.60 month
Full FY saving
x1000'VND
USD
PLANNED SAVING
434,107
20,457
ACTUAL SAVING
398,645
18,786
YTD Saving
x1000'VND
USD
PLANNED SAVING
2,305,942
108,668
ACTUAL SAVING
2,117,574
99,791
31,023
12 month
PQ27(Bivina)
Parameter Value
Production v
144,361
Extract of 1hL
10
Total extract
1,420,512
% brewery los
0.53
Equivalent to
7,529
Equivalent to
765
658,313
Unit
hL
kg
kg
kg
hL
TIEN GIANG
LATION
HOME
SAVING CALCULATION
PLANNED SAVING
[x1000'VND]
ACTUAL SAVING
[x1000'VND]
Calculated data
dd/mm/yy
dd/mm/yy
Hl
Auto updated data

Volume produce YTD
extract loss YTD :
FY ran over :
Brewing var YTD :
104,284
4.17
43.0
215,135
VND/Hl
%
%
VND
29,103
x1000'VND
USD
PLANNED SAVING
501,746
23,645
FORESEEN SAVING
144,002
6,786
x1000'VND
PLANNED SAVING
ACTUAL SAVING
USD
1,797,923
84,728
516,008
24,317
[x1000'VND]
[x1000'VND]
104,284 Hl
4.17
43.0
month
ted data)
215,135 VND/Hl
29,103 Hl
23,645
6,786
lculated data)
84,728
24,317
PLANT :

FY :
2012/2013
FORMULAS
Starting point :
Target :
Actual :
a
b
c
V1
V2
P1
P2
%
%
%
Hl
Hl
VND/Hl
VND/Hl
Input data
BUDGET FIGURES
Input data
Start FY date :
End FY date :
1-Jan-13
31-Dec-13
Volume Larue produced target:

Larue brewing var budget :
FY target :
Exchange rate:
1USD =
SAVING CALCULATION
Starting point:
03-Jul-13
-
dd/mm/yy
hl
85,030
218,938
4.35
5.13
21,220
Target:
Actual :
1,130 hl
1,130 hl

6.03 month
37.37 month
Full FY saving
x1000'VND
USD
PLANNED SAVING
497,549
23,447
ACTUAL SAVING
479,109
22,578
YTD Saving
x1000'VND
USD
PLANNED SAVING
3,081,508
145,217
ACTUAL SAVING
2,967,301
139,835
952,924
44,907
185,103
12 month
PQ29(Larue)
Parameter Value
Production v
205,506
Extract of 1h
11
Total extract
2,200,969
% brewery los
1
Equivalent to
12,105
Equivalent to
1,130
Unit
hL
kg
kg
kg
hL
TIEN GIANG
LATION
HOME
SAVING CALCULATION
PLANNED SAVING
[x1000'VND]
ACTUAL SAVING
[x1000'VND]
Calculated data
dd/mm/yy
dd/mm/yy
Hl
Auto updated data

Volume produce YTD
extract loss YTD :
FY ran over :
Brewing var YTD :
134,937
2.54
43.0
210,824
VND/Hl
%
%
VND
37,657
x1000'VND
USD
PLANNED SAVING
(145,207)
(6,843)
FORESEEN SAVING
143,695
6,772
x1000'VND
PLANNED SAVING
ACTUAL SAVING
USD
(520,326)
(24,521)
514,908
24,265
[x1000'VND]
[x1000'VND]
134,937 Hl
2.54
43.0
month
ted data)
210,824 VND/Hl
37,657 Hl
(6,843)
6,772
lculated data)
(24,521)
24,265
PLANT :
OPI LOSS CALCULATION

FY :
2012/2013
FORMULAS
Starting point :
Target :
Actual :
Cost per DThr :
Exchange rate :
Starting point :
Target :
Actual :
Eff working time YTD :
Eff working time last year :
Cost per DThr :
Exchange rate :
1USD =
1USD =
a
b
c
P
R
a
b
c
E1
E2
P
R
min/month
min/month
min/month
USD/DThr
VND
%OPI
% OPI
%OPI
Min
Min
USD/DThr
VND
Input data
BUDGET FIGURES
Input data
Start FY date :
End FY date :
Eff Working time last year :
Cost per DThr :
OPI NONA last year :
OPI NONA target :
Exchange rate:
1USD =
1-Jan-13
31-Dec-13
389,170
123.31
83.8
85
21220
SAVING CALCULATION
Starting point:
Target:
Actual :
12-Feb-13
dd/mm/yy
102.13 min/month
0
min/month
min/month
# of month the project contributes full FY :

# of month the project contributes YTD :
10.73 month
42.07 month
Full FY Saving
x1000'VND
USD
PLANNED SAVING
47,803
2,253
ACTUAL SAVING
47,803
2,253
YTD Saving
x1000'VND
USD
PLANNED SAVING
187,350
8,829
ACTUAL SAVING
187,350
8,829
2,519
Problem / background
BD Wrap Around
Downtime: 1699 pht / 3 thng (8, 9, 10 - 2012).
Tn sut: 61 ln / 3 thng (8, 9, 10 - 2012).
Cc Breakdown down xy ra ti cc Functional group sau:
Carton fomation unit 11 ln/thng
Carton magazin unit 7 ln/thng
Separator unit 3 ln/thng
% OPI loss contribution 1.59%
Target setting (SMART)
Team chn Functional Groups: Carton formation unit c s ln Break down nhiu hn c
cc Functional Groups cn li.
Carton fomation unit 11 ln/thng
0 ln/thng
Loi b nhng Failure mode sau:
Chains (transmission)MIS-ALIGNMENT - YC04:
5 ln/thng gim cn
Printed circuit board ELECTRONICAL FAILURE - YC17: 4 ln/ thng gim cn

Proximity switch ELECTRONICAL FAILURE - YC17:
1 ln/thng gim cn
Nozzles DIRT - YC32:
1 ln/ thng gim cn
Target date for completion
TIEN GIANG
HOME
SAVING
PLANNED SAVING
= (a-b)*12*R*P/(60*1000)
ACTUAL SAVING
= (a-c)*12*R*P/(60*1000)
SAVING
PLANNED SAVING
= (a-b)/100*E1*P*R/(60*1000)
ACTUAL SAVING
= (a-c)/100*E2*P*R/(60*1000)
Calculated data
dd/mm/yy
dd/mm/yy
Auto updated data

Eff Working time YTD :
OPI NONA YTD :
FY ran over :
184,805
69.2
43.0
min
USD/hr
%
%
VND
Eff working time foreseen :
51,573
KPI - Full FY
x1000'VND
PLANNED SAVING
203,658
FORESEEN SAVING
(328,368)
USD
9,597
(15,474)
x1000'VND
729,776
PLANNED SAVING
ACTUAL SAVING
(1,176,651)
trung bnh 20 ln / thng.
n Break down nhiu hn cc
n/thng gim cn
0 ln/thng
USD
34,391
(55,450)
thng gim cn
thng gim cn
n/ thng gim cn
0 ln/thng
0 ln/thng
0 ln/thng
60*1000)
[x1000'VND]
60*1000)
[x1000'VND]
R/(60*1000)
[x1000'VND]
R/(60*1000)
[x1000'VND]
184,805 Min
69.2
43.0
month
51,573 Min
ted data)
9,597
(15,474)
lculated data)
34,391
(55,450)
PLANT :

FY :
2012/2013
FORMULAS
Starting point :
Target :
Actual :
Cost per DThr :
Exchange rate :
Starting point :
Target :
Actual :
Cost per DThr :
Exchange rate :
1USD =
1USD =
a
b
c
P
R
a
b
c
E1
E2
P
R
min/month
min/month
min/month
USD/DThr
VND
%OPI
% OPI
%OPI
Min
Min
USD/DThr
VND
Input data
BUDGET FIGURES
Input data
Start FY date :
End FY date :
Cost per DThr :
OPI NONA target :
Exchange rate:
1USD =
1-Jan-13
31-Dec-13
389,170
123.31
83.8
85
21220
SAVING CALCULATION
Starting point:
Target:
Actual :
04-Aug-13
dd/mm/yy
267.08
min/month
min/month
24.28
min/month

4.97 month
36.30 month
Full FY Saving
x1000'VND
USD
PLANNED SAVING
57,848
2,726
ACTUAL SAVING
52,589
2,478
YTD Saving
x1000'VND
USD
PLANNED SAVING
422,795
19,924
ACTUAL SAVING
384,359
18,113
5,987.78
Starting Point:
Target:
Tn sut Breakdown
Down time
Breakdown ti Air distribution l 11 ln/ thng

Gim tn sut Breakdown ca Air distribution valve t 11 ln /thng xung
25 Ln / thng 2/2013
607 pht / thng 2 /2013
TIEN GIANG
HOME
SAVING
PLANNED SAVING
= (a-b)*12*R*P/(60*1000)
ACTUAL SAVING
= (a-c)*12*R*P/(60*1000)
SAVING
PLANNED SAVING
= (a-b)/100*E1*P*R/(60*1000)
ACTUAL SAVING
= (a-c)/100*E2*P*R/(60*1000)
Calculated data
dd/mm/yy
dd/mm/yy
Auto updated data

OPI NONA YTD :
FY ran over :
184,805
69.2
43.0
min
USD/hr
%
%
VND
51,573
KPI - Full FY
x1000'VND
PLANNED SAVING
203,658
FORESEEN SAVING
(328,368)
USD
9,597
(15,474)
x1000'VND
PLANNED SAVING
ACTUAL SAVING
valve t 11 ln /thng xung cn 0 ln/thng.
729,776
(1,176,651)
USD
34,391
(55,450)
60*1000)
[x1000'VND]
60*1000)
[x1000'VND]
R/(60*1000)
[x1000'VND]
R/(60*1000)
[x1000'VND]
184,805 Min
69.2
43.0
month
51,573 Min
ted data)
9,597
(15,474)
lculated data)
34,391
(55,450)
PLANT :

FY :
2012/2013
FORMULAS
Starting point :
Target :
Actual :
Cost per DThr :
Exchange rate :
Starting point :
Target :
Actual :
Cost per DThr :
Exchange rate :
1USD =
1USD =
a
b
c
P
R
a
b
c
E1
E2
P
R
min/month
min/month
min/month
USD/DThr
VND
%OPI
% OPI
%OPI
Min
Min
USD/DThr
VND
Input data
BUDGET FIGURES
Input data
Start FY date :
End FY date :
Cost per DThr :
OPI NONA target :
Exchange rate:
1USD =
1-Jan-13
31-Dec-13
389,170
123.31
83.8
85
21220
SAVING CALCULATION
Starting point:
Target:
Actual :
03-Mar-13
dd/mm/yy
96
min/month
min/month
13.71 min/month

10.10 month
41.43 month
Full FY Saving
x1000'VND
USD
PLANNED SAVING
42,284
1,993
ACTUAL SAVING
36,243
1,708
YTD Saving
x1000'VND
USD
PLANNED SAVING
173,461
8,174
ACTUAL SAVING
148,681
7,007
2,029.28
The "Seamingroll" component of Seamer is cause breakdown (OPI loss 0.56% at Canning line in Jan/13
Breakdown at Seamer in Jan/13 : 9 times/194 min
Breakdown by Seaming roll Component at Seamer in Jan/13 : 7/times/ 96 min
7 breakdown times by "Seaming roll " component of Seamer in Jan/13
No breakdown by ' Seaming roll" component of Seamer at canning line
TIEN GIANG
HOME
SAVING
PLANNED SAVING
= (a-b)*12*R*P/(60*1000)
ACTUAL SAVING
= (a-c)*12*R*P/(60*1000)
SAVING
PLANNED SAVING
= (a-b)/100*E1*P*R/(60*1000)
ACTUAL SAVING
= (a-c)/100*E2*P*R/(60*1000)
Calculated data
dd/mm/yy
dd/mm/yy
Auto updated data

OPI NONA YTD :
FY ran over :
184,805
69.2
43.0
min
USD/hr
%
%
VND
51,573
KPI - Full FY
x1000'VND
PLANNED SAVING
203,658
FORESEEN SAVING
(328,368)
USD
9,597
(15,474)
x1000'VND
PLANNED SAVING
ACTUAL SAVING
6% at Canning line in Jan/13)
729,776
(1,176,651)
USD
34,391
(55,450)
60*1000)
[x1000'VND]
60*1000)
[x1000'VND]
R/(60*1000)
[x1000'VND]
R/(60*1000)
[x1000'VND]
184,805 Min
69.2
43.0
month
51,573 Min
ted data)
9,597
(15,474)
lculated data)
34,391
(55,450)
PLANT :

FY :
2012/2013
FORMULAS
Starting point :
Target :
Actual :
Cost per DThr :
Exchange rate :
Starting point :
Target :
Actual :
Cost per DThr :
Exchange rate :
1USD =
1USD =
a
b
c
P
R
a
b
c
E1
E2
P
R
min/month
min/month
min/month
USD/DThr
VND
%OPI
% OPI
%OPI
Min
Min
USD/DThr
VND
Input data
BUDGET FIGURES
Input data
Start FY date :
End FY date :
Cost per DThr :
OPI NONA target :
Exchange rate:
1USD =
1-Jan-13
31-Dec-13
389,170
123.31
83.8
85
21220
SAVING CALCULATION
Starting point:
Target:
Actual :
12-Feb-13
dd/mm/yy
383.00 min/month
-
min/month
47.88 min/month

10.73 month
42.07 month
Full FY Saving
x1000'VND
USD
PLANNED SAVING
179,273
8,448
ACTUAL SAVING
156,864
7,392
YTD Saving
x1000'VND
USD
PLANNED SAVING
702,617
33,111
ACTUAL SAVING
614,789
28,972
8,264.64
Palletiser:
Down time
383 min/Oct_12
Frequency
12 times/Oct_12
Breakdowns happening at Function group include:
Centring unit L=1300 x 1100
Electrical component:
Layer grouping table L=710:
Row grouping station dead plate top:
% OPI loss contribution
0.0106

Team select Centring unit L=1300 x 1100 Functional Groups with the number of times Break down mo
Eradicate failure modes:

- Cylinders, Pneumatic LOOSEN
- Proximity switch BLOCKADE - YC29
- Air Connector BLOCKADE - YC29
- Proximity switch BROKEN PARTS - YC03
- Photocell controller OPERATING OUTSIDE SPECIFICATION - YC10
Target date for completion
TIEN GIANG
HOME
SAVING
PLANNED SAVING
= (a-b)*12*R*P/(60*1000)
ACTUAL SAVING
= (a-c)*12*R*P/(60*1000)
SAVING
PLANNED SAVING
= (a-b)/100*E1*P*R/(60*1000)
ACTUAL SAVING
= (a-c)/100*E2*P*R/(60*1000)
Calculated data
dd/mm/yy
dd/mm/yy
Auto updated data

OPI NONA YTD :
FY ran over :
184,805
69.2
43.0
min
USD/hr
%
%
VND
51,573
KPI - Full FY
x1000'VND
PLANNED SAVING
203,658
FORESEEN SAVING
(328,368)
USD
9,597
(15,474)
x1000'VND
729,776
PLANNED SAVING
(1,176,651)
ACTUAL SAVING
9 times/
1 times/
1 times/
1 times/
month
month
month
month
mber of times Break down more than the rest of the Functional Groups
USD
34,391
(55,450)
60*1000)
[x1000'VND]
60*1000)
[x1000'VND]
R/(60*1000)
[x1000'VND]
R/(60*1000)
[x1000'VND]
184,805 Min
69.2
43.0
month
51,573 Min
ted data)
9,597
(15,474)
lculated data)
34,391
(55,450)
PLANT :

FY :
2012/2013
FORMULAS
Starting point :
Target :
Actual :
Cost per DThr :
Exchange rate :
Starting point :
Target :
Actual :
Cost per DThr :
Exchange rate :
1USD =
1USD =
a
b
c
P
R
a
b
c
E1
E2
P
R
min/month
min/month
min/month
USD/DThr
VND
%OPI
% OPI
%OPI
Min
Min
USD/DThr
VND
Input data
BUDGET FIGURES
Input data
Start FY date :
End FY date :
Cost per DThr :
OPI NONA target :
Exchange rate:
1USD =
1-Jan-13
31-Dec-13
389,170
123.31
83.8
85
21220
SAVING CALCULATION
Starting point:
Target:
Actual :
03-Mar-13
dd/mm/yy
75
min/month
min/month
30
min/month

10.10 month
41.43 month
Full FY Saving
x1000'VND
USD
PLANNED SAVING
33,034
1,557
ACTUAL SAVING
19,821
934
YTD Saving
x1000'VND
PLANNED SAVING
ACTUAL SAVING
USD
135,517
6,386
81,310
3,832
1,109.76
Minor stop failure modes have highest frequency (From 4/12/12 to 8/12/12) :
Can toppled on table conveyor 3 times / shift
Can toppled from plastic conveyor transfer to cable conveyor : 2 times / shift
Launch team to eradicate 2 failure modes follow:
Can toppled on table conveyor 0 time / shift
Can toppled from plastic conveyor transfer to cable conveyor : 0 times / shift
TIEN GIANG
HOME
SAVING
PLANNED SAVING
= (a-b)*12*R*P/(60*1000)
ACTUAL SAVING
= (a-c)*12*R*P/(60*1000)
SAVING
PLANNED SAVING
= (a-b)/100*E1*P*R/(60*1000)
ACTUAL SAVING
= (a-c)/100*E2*P*R/(60*1000)
Calculated data
dd/mm/yy
dd/mm/yy
Auto updated data

OPI NONA YTD :
FY ran over :
184,805
69.2
43.0
min
USD/hr
%
%
VND
51,573
/12 to 8/12/12) :
r : 2 times / shift
r : 0 times / shift
KPI - Full FY
x1000'VND
PLANNED SAVING
203,658
FORESEEN SAVING
(328,368)
USD
9,597
(15,474)
x1000'VND
PLANNED SAVING
ACTUAL SAVING
729,776
(1,176,651)
USD
34,391
(55,450)
60*1000)
[x1000'VND]
60*1000)
[x1000'VND]
R/(60*1000)
[x1000'VND]
R/(60*1000)
[x1000'VND]
184,805 Min
69.2
43.0
month
51,573 Min
ted data)
9,597
(15,474)
lculated data)
34,391
(55,450)
PLANT :

FY :
2012/2013
FORMULAS
Starting point :
Target :
Actual :
Cost per DThr :
Exchange rate :
Starting point :
Target :
Actual :
Cost per DThr :
Exchange rate :
1USD =
1USD =
a
b
c
P
R
a
b
c
E1
E2
P
R
min/month
min/month
min/month
USD/DThr
VND
%OPI
% OPI
%OPI
Min
Min
USD/DThr
VND
Input data
BUDGET FIGURES
Input data
Start FY date :
End FY date :
Cost per DThr :
OPI NONA target :
Exchange rate:
1USD =
1-Jan-13
31-Dec-13
57,510
1,266.14
59.5
65
21220
SAVING CALCULATION
Starting point:
Target:
Actual :
25-Jan-13
dd/mm/yy
84.75 min/month
0
min/month
min/month

11.33 month
42.67 month
Full FY Saving
x1000'VND
USD
PLANNED SAVING
430,104
20,269
ACTUAL SAVING
430,104
20,269
YTD Saving
x1000'VND
USD
PLANNED SAVING
1,619,214
76,306
ACTUAL SAVING
1,619,214
76,306
21,461

*Team chn 2 Functional Groups: Crowner - crown cork hopper, Filling valve c s ln Break down nhi
1-Filling valve : 05 ln/thng gim cn 0 ln/thng
2- Crowner - crown cork hopper:04 ln/thng gim cn 0 ln/thng
Loi b Failure mode : O-Rings - Tear
Loi b Failure mode: Small hopper - Blockage
TIEN GIANG
HOME
SAVING
PLANNED SAVING
= (a-b)*12*R*P/(60*1000)
ACTUAL SAVING
= (a-c)*12*R*P/(60*1000)
SAVING
PLANNED SAVING
= (a-b)/100*E1*P*R/(60*1000)
ACTUAL SAVING
= (a-c)/100*E2*P*R/(60*1000)
Calculated data
dd/mm/yy
dd/mm/yy
Auto updated data

OPI NONA YTD :
FY ran over :
155,540
48
43.0
min
USD/hr
%
%
VND
43,406
KPI - Full FY
x1000'VND
PLANNED SAVING
1,416,387
FORESEEN SAVING
(2,235,260)
USD
66,748
(105,337)
x1000'VND
PLANNED SAVING
ACTUAL SAVING
USD
5,075,387
239,179
(8,009,681)
(377,459)
ve c s ln Break down nhiu hn cc Functional Groups cn li:

OPI contribution: 4.83%
60*1000)
[x1000'VND]
60*1000)
[x1000'VND]
R/(60*1000)
[x1000'VND]
R/(60*1000)
[x1000'VND]
155,540 Min
48
43.0
%
month
43,406 Min
ted data)
66,748
(105,337)
lculated data)
239,179
(377,459)
PLANT :

FY :
2012/2013
FORMULAS
Starting point :
Target :
Actual :
Cost per DThr :
Exchange rate :
Starting point :
Target :
Actual :
Cost per DThr :
Exchange rate :
1USD =
1USD =
a
b
c
P
R
a
b
c
E1
E2
P
R
min/month
min/month
min/month
USD/DThr
VND
%OPI
% OPI
%OPI
Min
Min
USD/DThr
VND
Input data
BUDGET FIGURES
Input data
Start FY date :
End FY date :
Cost per DThr :
OPI NONA target :
Exchange rate:
1USD =
1-Jan-13
31-Dec-13
57,510
1,266.14
59.5
65
21220
SAVING CALCULATION
Starting point:
Target:
Actual :
15-Oct-13
dd/mm/yy
68.33 min/month
0
min/month
min/month

2.57 month
33.90 month
Full FY Saving
x1000'VND
USD
PLANNED SAVING
78,538
3,701
ACTUAL SAVING
78,538
3,701
YTD Saving
x1000'VND
USD
PLANNED SAVING
1,037,309
48,884
ACTUAL SAVING
1,037,309
48,884
17,304
38,765
Bottle Packer : Down time
205 pht / thng 8 /2013
Tn sut
06 Ln / thng 8/2013
Bottle table
Gripper head
Chain tension adjustment
Connection for distributor of group valve
02 ln/ thng
02 ln/ thng
01 ln/thng
1 ln/thng
% OPI loss contribution 1.3 %
( 1 thng 8/2013 )

*Team chn 1 Functional Groups: Bottle table c s ln Break down nhiu hn cc Functional Groups c
1-Bottle table : 02 ln/thng gim cn 0 ln/thng
TIEN GIANG
HOME
SAVING
PLANNED SAVING
= (a-b)*12*R*P/(60*1000)
ACTUAL SAVING
= (a-c)*12*R*P/(60*1000)
SAVING
PLANNED SAVING
= (a-b)/100*E1*P*R/(60*1000)
ACTUAL SAVING
= (a-c)/100*E2*P*R/(60*1000)
Calculated data
dd/mm/yy
dd/mm/yy
Auto updated data

OPI NONA YTD :
FY ran over :
155,540
48
43.0
min
USD/hr
%
%
VND
43,406
KPI - Full FY
x1000'VND
PLANNED SAVING
1,416,387
FORESEEN SAVING
(2,235,260)
USD
66,748
(105,337)
x1000'VND
PLANNED SAVING
ACTUAL SAVING
hng 8/2013 )
hn cc Functional Groups cn li:
USD
5,075,387
239,179
(8,009,681)
(377,459)
OPI contribution: 0.13 %
60*1000)
[x1000'VND]
60*1000)
[x1000'VND]
R/(60*1000)
[x1000'VND]
R/(60*1000)
[x1000'VND]
155,540 Min
48
43.0
%
month
43,406 Min
ted data)
66,748
(105,337)
lculated data)
239,179
(377,459)
PLANT :

FY :
2012/2013
FORMULAS
Starting point :
Target :
Actual :
Cost per DThr :
Exchange rate :
Starting point :
Target :
Actual :
Cost per DThr :
Exchange rate :
1USD =
1USD =
a
b
c
P
R
a
b
c
E1
E2
P
R
min/month
min/month
min/month
USD/DThr
VND
%OPI
% OPI
%OPI
Min
Min
USD/DThr
VND
Input data
BUDGET FIGURES
Input data
Start FY date :
End FY date :
Cost per DThr :
OPI NONA target :
Exchange rate:
1USD =
1-Jan-13
31-Dec-13
389,170
123.31
83.8
85
21220
SAVING CALCULATION
Starting point:
Target:
Actual :
18-Jan-13
dd/mm/yy
23.33 min/month
0
min/month
min/month

11.57 month
42.90 month
Full FY Saving
x1000'VND
PLANNED SAVING
ACTUAL SAVING
USD
11,770
555
9,248
436
YTD Saving
x1000'VND
USD
PLANNED SAVING
43,653
2,057
ACTUAL SAVING
34,299
1,616
452.13
25,140.32
Alarm "Separation driver motor 2" caused by
"Wheel" component of Wrap around at canning line

To eradication breakdowns caused by
TIEN GIANG
HOME
SAVING
PLANNED SAVING
= (a-b)*12*R*P/(60*1000)
ACTUAL SAVING
= (a-c)*12*R*P/(60*1000)
SAVING
PLANNED SAVING
= (a-b)/100*E1*P*R/(60*1000)
ACTUAL SAVING
= (a-c)/100*E2*P*R/(60*1000)
Calculated data
dd/mm/yy
dd/mm/yy
Auto updated data

OPI NONA YTD :
FY ran over :
184,805
69.2
43.0
min
USD/hr
%
%
VND
51,573
KPI - Full FY
x1000'VND
PLANNED SAVING
203,658
FORESEEN SAVING
(328,368)
USD
9,597
(15,474)
x1000'VND
PLANNED SAVING
ACTUAL SAVING
729,776
(1,176,651)
USD
34,391
(55,450)
60*1000)
[x1000'VND]
60*1000)
[x1000'VND]
R/(60*1000)
[x1000'VND]
R/(60*1000)
[x1000'VND]
184,805 Min
69.2
43.0
month
51,573 Min
ted data)
9,597
(15,474)
lculated data)
34,391
(55,450)
PLANT :

FY :
2012/2013
FORMULAS
Starting point :
Target :
Actual :
Cost per DThr :
Exchange rate :
Starting point :
Target :
Actual :
Cost per DThr :
Exchange rate :
1USD =
1USD =
a
b
c
P
R
a
b
c
E1
E2
P
R
min/month
min/month
min/month
USD/DThr
VND
%OPI
% OPI
%OPI
Min
Min
USD/DThr
VND
Input data
BUDGET FIGURES
Input data
Start FY date :
End FY date :
Cost per DThr :
OPI NONA target :
Exchange rate:
1USD =
1-Jan-13
31-Dec-13
389,170
123.31
83.8
85
21220
SAVING CALCULATION
Starting point:
Target:
Actual :
18-Mar-13
dd/mm/yy
80.00 min/month
0
min/month
min/month

9.60 month
40.93 month
Full FY Saving
x1000'VND
USD
PLANNED SAVING
33,492
1,578
ACTUAL SAVING
31,399
1,480
YTD Saving
x1000'VND
USD
PLANNED SAVING
142,807
6,730
ACTUAL SAVING
133,881
6,309
1,849.60
26,537.80
Alarm "Separation driver motor 2" caused by

To eradication breakdowns caused by
TIEN GIANG
HOME
SAVING
PLANNED SAVING
= (a-b)*12*R*P/(60*1000)
ACTUAL SAVING
= (a-c)*12*R*P/(60*1000)
SAVING
PLANNED SAVING
= (a-b)/100*E1*P*R/(60*1000)
ACTUAL SAVING
= (a-c)/100*E2*P*R/(60*1000)
Calculated data
dd/mm/yy
dd/mm/yy
Auto updated data

OPI NONA YTD :
FY ran over :
184,805
69.2
43.0
min
USD/hr
%
%
VND
51,573
KPI - Full FY
x1000'VND
PLANNED SAVING
203,658
FORESEEN SAVING
(328,368)
USD
9,597
(15,474)
x1000'VND
PLANNED SAVING
ACTUAL SAVING
729,776
(1,176,651)
USD
34,391
(55,450)
60*1000)
[x1000'VND]
60*1000)
[x1000'VND]
R/(60*1000)
[x1000'VND]
R/(60*1000)
[x1000'VND]
184,805 Min
69.2
43.0
month
51,573 Min
ted data)
9,597
(15,474)
lculated data)
34,391
(55,450)
PLANT :

FY :
2012/2013
FORMULAS
Starting point :
Target :
Actual :
Cost per DThr :
Exchange rate :
Starting point :
Target :
Actual :
Cost per DThr :
Exchange rate :
1USD =
1USD =
a
b
c
P
R
a
b
c
E1
E2
P
R
min/month
min/month
min/month
USD/DThr
VND
%OPI
% OPI
%OPI
Min
Min
USD/DThr
VND
Input data
BUDGET FIGURES
Input data
Start FY date :
End FY date :
Cost per DThr :
OPI NONA target :
Exchange rate:
1USD =
1-Jan-13
31-Dec-13
389,170
123.31
83.8
85
21220
SAVING CALCULATION
Starting point:
Target:
Actual :
31-Jul-13
dd/mm/yy
210.33 min/month
0
min/month
7.79 min/month

5.10 month
36.43 month
Full FY Saving
x1000'VND
USD
PLANNED SAVING
46,780
2,205
ACTUAL SAVING
45,047
2,123
YTD Saving
x1000'VND
USD
PLANNED SAVING
334,186
15,749
ACTUAL SAVING
321,809
15,165
4,994.99
29,683.19
Breakdowns caused by loose "Conveyor guide" component of seamer
Down
time 27
631
min/3 month (May, Jun, Jul/2013)
Frequence
times
OPI loss contribution 0.56%

To eradication breakdowns caused by loose "Conveyor guide" component of seamer
OPI loss contribution 0.56.%
TIEN GIANG
HOME
SAVING
PLANNED SAVING
= (a-b)*12*R*P/(60*1000)
ACTUAL SAVING
= (a-c)*12*R*P/(60*1000)
SAVING
PLANNED SAVING
= (a-b)/100*E1*P*R/(60*1000)
ACTUAL SAVING
= (a-c)/100*E2*P*R/(60*1000)
Calculated data
dd/mm/yy
dd/mm/yy
Auto updated data

OPI NONA YTD :
FY ran over :
184,805
69.2
43.0
min
USD/hr
%
%
VND
51,573
of seamer
KPI - Full FY
x1000'VND
PLANNED SAVING
203,658
FORESEEN SAVING
(328,368)
USD
9,597
(15,474)
x1000'VND
PLANNED SAVING
ACTUAL SAVING
729,776
(1,176,651)
USD
34,391
(55,450)
60*1000)
[x1000'VND]
60*1000)
[x1000'VND]
R/(60*1000)
[x1000'VND]
R/(60*1000)
[x1000'VND]
184,805 Min
69.2
43.0
month
51,573 Min
ted data)
9,597
(15,474)
lculated data)
34,391
(55,450)
PLANT :

FY :
2012/2013
FORMULAS
Starting point :
Target :
Actual :
Cost per DThr :
Exchange rate :
Starting point :
Target :
Actual :
Cost per DThr :
Exchange rate :
1USD =
1USD =
a
b
c
P
R
a
b
c
E1
E2
P
R
min/month
min/month
min/month
USD/DThr
VND
%OPI
% OPI
%OPI
Min
Min
USD/DThr
VND
Input data
BUDGET FIGURES
Input data
Start FY date :
End FY date :
Cost per DThr :
OPI NONA target :
Exchange rate:
1USD =
1-Jan-13
31-Dec-13
389,170
123.31
83.8
85
21220
SAVING CALCULATION
Starting point:
Target:
Actual :
31-Oct-13
dd/mm/yy
423.82 min/month
0
min/month
47.09 min/month

2.03 month
33.37 month
Full FY Saving
x1000'VND
USD
PLANNED SAVING
37,581
1,771
ACTUAL SAVING
33,405
1,574
YTD Saving
x1000'VND
USD
PLANNED SAVING
616,700
29,062
ACTUAL SAVING
548,178
25,833
9,290.61
33,978.81
BD Seamer thng 10
Downtime: 518 pht /thng.
Tn sut: 11 ln /thng.
trung bnh 3 ln / thng.
Upper part 9 ln/thng.
FHI 1 ln/thng.
Lip depiling 1 ln/thng.
Team chn Functional Groups: Upper part c s ln Break down nhiu hn cc
cc Functional Groups cn li.
Upper part 9 ln/thng.
0 ln/thng.
Loi b nhng Failure mode sau:
Sealing Defect YC-31 t 7 ln/thng
gim cn 0 ln/thng.
BLOCKADE - YC29 t 2 ln/thng
gim cn 0 ln/thng.
TIEN GIANG
HOME
SAVING
PLANNED SAVING
= (a-b)*12*R*P/(60*1000)
ACTUAL SAVING
= (a-c)*12*R*P/(60*1000)
SAVING
PLANNED SAVING
= (a-b)/100*E1*P*R/(60*1000)
ACTUAL SAVING
= (a-c)/100*E2*P*R/(60*1000)
Calculated data
dd/mm/yy
dd/mm/yy
Auto updated data

OPI NONA YTD :
FY ran over :
184,805
69.2
43.0
min
USD/hr
%
%
VND
51,573
m cn 0 ln/thng.
m cn 0 ln/thng.
KPI - Full FY
x1000'VND
PLANNED SAVING
203,658
FORESEEN SAVING
(328,368)
USD
9,597
(15,474)
x1000'VND
PLANNED SAVING
ACTUAL SAVING
729,776
(1,176,651)
USD
34,391
(55,450)
60*1000)
[x1000'VND]
60*1000)
[x1000'VND]
R/(60*1000)
[x1000'VND]
R/(60*1000)
[x1000'VND]
184,805 Min
69.2
43.0
month
51,573 Min
ted data)
9,597
(15,474)
lculated data)
34,391
(55,450)
PLANT :
PRODUCTIVITY SAVING CALCULATION

FY :
2012/2013
FORMULAS
Starting point :
Target :
Actual :
FTE target :
FTE actual :
Personel cost budget :
Personel cost actual :
a
b
c
F1
F2
P1
P2
Hl/fte
Hl/fte
Hl/fte
FTE
FTE
VND/Hl
VND/Hl
Input data
BUDGET FIGURES
Input data
Start FY date :
End FY date :
1-Jan-13
31-Dec-13
FTE target :
Personel cost budget :
Productivity last FY :
Productivity target :
Exchange rate:
161
11,430
4956
3786
1USD =
SAVING CALCULATION
Starting point:
29-Apr-13
1064
dd/mm/yy
Hl/fte
21220
Target:
Actual :
1298
Hl/fte
1298
Hl/fte

month
40
month
Full FY Saving
x1000'VND
USD
PLANNED SAVING
294,241
13,866
ACTUAL SAVING
295,441
13,923
YTD Saving
x1000'VND
USD
PLANNED SAVING
1,418,576
66,851
ACTUAL SAVING
1,424,363
67,124
GenInfo
Volumes
Name
Oct 2013
Sep 2013
Aug 2013
Jul 2013
Jun 2013
May 2013
Apr 2013
Mar 2013
Feb 2013
Jan 2013
Dec 2012
Nov 2012
Oct 2012
430,596
432,353
Actual
Permanent (ft Fixed Term (fteFlexible (fte)
43,548
28,803
49,706
35,036
30,828
39,146
27,437
36,605
63,521
58,428
62,001
65,922
31.7
29.3
30
32.9
28.8
28.5
29.3
5.3
3
4.5
7.8
6.2
5.1
5.2
0
0
0
0
0
0
0
There are too much walking and waiting : the layout has not been conceived to support
There are no standards: workers use difference techniques, procedures and methods.
Op don't have time to complete CILT OTIF and AM activities
Average operator saturation: 58.3%
Reduce 1 operator (from 6 to 5 operators per shift) by increasing saturation level of the
operators
Average operator saturation: >/= 70%
TIEN GIANG
LATION
HOME
SAVING CALCULATION
PLANNED SAVING
= (b-a)*F1*P1/1000)
ACTUAL SAVING
= (c-a)*F2*P2/1000
Calculated data
dd/mm/yy
dd/mm/yy
FTE/month
Auto updated data

FTE actual :
Productivity YTD :
FY ran over :
Personal cost actual :
208
3,174
43.0
8,870
VND/Hl
HL/fte
FTE foreseen :
Hl/fte
VND
58
x1000'VND
PLANNED SAVING
FORESEEN SAVING
USD
(2,152,982)
(101,460)
(918,847)
(43,301)
x1000'VND
Total (fte)
USD
PLANNED SAVING
(7,714,852)
(363,565)
ACTUAL SAVING
(3,292,535)
(155,162)
Target (fte)
28.81
26.45
27.66
28.33
28.83
37
32.3
34.4
40.7
34.9
33.5
34.5
Manhours (hr)
33 33
33
33
33
33
33
33
33
33
33
33
33
been conceived to support productivity

procedures and methods.
asing saturation level of the other
6171
5614
6048
6742
6709
6383
5571
5936
7019
6026
5779
5943
productivity
1,512
1,089
1,797
1,237
1,069
1,058
849
1,064
1,561
1,674
1,851
1,911
1,298
[x1000'VND]
[x1000'VND]
208 FTE/month
3,174 Hl/fte
43.0
ted data)
month
8,870 VND/Mj
58 FTE/year
(101,460)
(43,301)
lculated data)
(363,565)
(155,162)
PLANT :

FY :
2012/2013
FORMULAS
Starting point :
Target :
Actual :
Cost per DThr :
Exchange rate :
Starting point :
Target :
Actual :
Cost per DThr :
Exchange rate :
1USD =
1USD =
a
b
c
P
R
a
b
c
E1
E2
P
R
min/month
min/month
min/month
USD/DThr
VND
%OPI
% OPI
%OPI
Min
Min
USD/DThr
VND
Input data
BUDGET FIGURES
Input data
Start FY date :
End FY date :
Cost per DThr :
OPI NONA target :
Exchange rate:
1USD =
1-Jan-13
31-Dec-13
57,510
1,266.14
59.5
65
21220
SAVING CALCULATION
Starting point:
Target:
Actual :
15-Jun-13
dd/mm/yy
200.00 min/month
50
min/month
50
min/month

6.63 month
37.97 month
Full FY Saving
x1000'VND
USD
PLANNED SAVING
445,553
20,997
ACTUAL SAVING
445,553
20,997
YTD Saving
x1000'VND
USD
PLANNED SAVING
2,550,173
120,178
ACTUAL SAVING
2,550,173
120,178
806,025
806,025
Cha c thi gian tiu chun cho vic change over ti my
Khi change over phi n 2 ngi thc hin change over khun gp
Thi change over khun gp hin ti l cn 02 ngi lm trong thi gian 20 pht
Khng an ton cho nhn vin trong khi change over
Cc khun gp trn cao kh tip cn bo dng v khng an ton
Xy dng tiu chun cho vic change over
Cc thao tc trong khi change over phi an ton v n gin d s dng cho ngi vn
Thi change over khun gp l cn 01 ngi lm trong thi gian 10 pht
Cc thao tc trong khi change over phi an ton v n gin d s dng cho ngi vn
TIEN GIANG
HOME
SAVING
PLANNED SAVING
= (a-b)*12*R*P/(60*1000)
ACTUAL SAVING
= (a-c)*12*R*P/(60*1000)
SAVING
PLANNED SAVING
= (a-b)/100*E1*P*R/(60*1000)
ACTUAL SAVING
= (a-c)/100*E2*P*R/(60*1000)
Calculated data
dd/mm/yy
dd/mm/yy
Auto updated data

OPI NONA YTD :
FY ran over :
155,540
48
43.0
min
USD/hr
%
%
VND
43,406
KPI - Full FY
x1000'VND
PLANNED SAVING
1,416,387
FORESEEN SAVING
(2,235,260)
USD
66,748
(105,337)
x1000'VND
PLANNED SAVING
ACTUAL SAVING
ng thi gian 20 pht
ng an ton
n d s dng cho ngi vn hnh

gian 10 pht
n d s dng cho ngi vn hnh
USD
5,075,387
239,179
(8,009,681)
(377,459)
60*1000)
[x1000'VND]
60*1000)
[x1000'VND]
R/(60*1000)
[x1000'VND]
R/(60*1000)
[x1000'VND]
155,540 Min
48
43.0
%
month
43,406 Min
ted data)
66,748
(105,337)
lculated data)
239,179
(377,459)
PLANT :

FY :
2012/2013
FORMULAS
Starting point :
Target :
Actual :
Cost per DThr :
Exchange rate :
Starting point :
Target :
Actual :
Cost per DThr :
Exchange rate :
1USD =
1USD =
a
b
c
P
R
a
b
c
E1
E2
P
R
min/month
min/month
min/month
USD/DThr
VND
%OPI
% OPI
%OPI
Min
Min
USD/DThr
VND
Input data
BUDGET FIGURES
Input data
Start FY date :
End FY date :
Cost per DThr :
OPI NONA target :
Exchange rate:
1USD =
1-Jan-13
31-Dec-13
57,510
1,266.14
59.5
65
21220
SAVING CALCULATION
Starting point:
Target:
Actual :
07-Oct-13
dd/mm/yy
50.00 min/month
0
min/month
min/month

2.83 month
34.17 month
Full FY Saving
x1000'VND
USD
PLANNED SAVING
63,437
2,989
ACTUAL SAVING
63,437
2,989
YTD Saving
x1000'VND
USD
PLANNED SAVING
764,977
36,050
ACTUAL SAVING
764,977
36,050
268,675
268,675
Change over time - is fluctuated between different operator teams (5mins - 10 mins).
Change over standards are not systematic.

1. Build up systematic standards for change over (initial standards).
2. Fluctuation change over between teams not over 5 mins.
3. Reduce change over time by 10 mins (compare with initial standards)
TIEN GIANG
HOME
SAVING
PLANNED SAVING
= (a-b)*12*R*P/(60*1000)
ACTUAL SAVING
= (a-c)*12*R*P/(60*1000)
SAVING
PLANNED SAVING
= (a-b)/100*E1*P*R/(60*1000)
ACTUAL SAVING
= (a-c)/100*E2*P*R/(60*1000)
Calculated data
dd/mm/yy
dd/mm/yy
Auto updated data

OPI NONA YTD :
FY ran over :
155,540
48
43.0
min
USD/hr
%
%
VND
43,406
KPI - Full FY
x1000'VND
PLANNED SAVING
1,416,387
FORESEEN SAVING
(2,235,260)
USD
66,748
(105,337)
x1000'VND
PLANNED SAVING
ACTUAL SAVING
teams (5mins - 10 mins).
l standards)
USD
5,075,387
239,179
(8,009,681)
(377,459)
60*1000)
[x1000'VND]
60*1000)
[x1000'VND]
R/(60*1000)
[x1000'VND]
R/(60*1000)
[x1000'VND]
155,540 Min
48
43.0
%
month
43,406 Min
ted data)
66,748
(105,337)
lculated data)
239,179
(377,459)
PLANT :
ELECTRICITY SAVING CALCULATION

FY :
2012/2013
FORMULAS
Starting point :
Target :
Actual :
Cost per KWh budget :
Cost per KWh YTD:
a
b
c
V1
V2
P1
P2
KWh/hl
KWh/hl
KWh/hl
Hl
Hl
VND/Hl
VND/Hl
Input data
BUDGET FIGURES
Input data
Start FY date :
End FY date :
1-Jan-13
31-Dec-13

Electricity last FY :
Target FY :
Exchange rate:
1USD =
SAVING CALCULATION
Starting point:
01-Jul-13
0.03
dd/mm/yy
KWh/hl
701,164
1,096
7.74
7.7
21220
Target:
Actual :
0.015
KWh/hl
0.015
KWh/hl

month
37
month
Full FY Saving
x1000'VND
USD
PLANNED SAVING
5,860
276
ACTUAL SAVING
5,571
263
YTD Saving
x1000'VND
USD
PLANNED SAVING
35,958
1,695
ACTUAL SAVING
34,187
1,611
11,527
10,959
Starting Point:
Target:
Average electic consumption of WWTP at Sandfilter quite high 0.03 KW/Hl

Electric consumption of WWTP at Sandfilter is 0.015 KW/Hl WW
Trigger Point
Electric consumption of WWTP at Sandfilter is 0.015 KW/Hl WW
Follow up period: (6 Months after Team closed)

Followed-up by:
Nguyn Vn Hong
Root Cause:
Action Defined
Thi gian cc bm p lc ti Sandfilter hot ng nhiu
1 Kim tra kh nng t lc ( khng cn bm) ca sandfilter

2 Xc nh lu lng cn thit m Sandfilter phi hot ng ( m3/h)
3 Ci t li trng trnh PLC sao cho cc Pump p lc ch hot ng khi ph
v lu lng ra sng ln hn hot bng lng lng cn thit
TIEN GIANG
TION
HOME
SAVING CALCULATION
PLANNED SAVING
= (a-b)*V1*P1/1000)
ACTUAL SAVING
= (a-c)*V2*P2/1000
Calculated data
dd/mm/yy
dd/mm/yy
Hl
Auto updated data

Volume produce YTD :
Electricity YTD :
FY ran over :
Cost per KWh YTD :
495,866
9.56
43.0
1,042
VND/KWh
KWH/hl
Volume produced forseen :
KWH/hl
VND
138,381
x1000'VND
30,739
PLANNED SAVING
FORSEEN SAVING
USD
1,449
(262,432)
(12,367)
x1000'VND
PLANNED SAVING
ACTUAL SAVING
110,148
(940,380)
dfilter quite high 0.03 KW/Hl WW

0.015 KW/Hl WW
0.015 KW/Hl WW
a sandfilter
i hot ng ( m3/h)
p lc ch hot ng khi phao in ( ti b kh trng) mc high
lng cn thit
USD
5,191
(44,316)
[x1000'VND]
[x1000'VND]
495,866 Hl
9.56
KWh/Hl
43.0
month
ted data)
1,042 VND/KWh
138,381 Hl
1,449
(12,367)
lculated data)
5,191
(44,316)
PLANT :
WATER SAVING CALCULATION

FY :
2012/2013
FORMULAS
Starting point :
Target :
Actual :
Cost per HL water budget :
Cost per Hl water YTD:
a
b
c
V1
V2
P1
P2
Hl/Hl
Hl/Hl
Hl/Hl
Hl
Hl
VND/Hl
VND/Hl
Input data
BUDGET FIGURES
Input data
Start FY date :
End FY date :
1-Jan-13
31-Dec-13

Cost per Hl budget :
Water last FY :
Target FY :
Exchange rate:
1USD =
SAVING CALCULATION
Starting point:
01-Jul-13
0.31
dd/mm/yy
Hl/Hl
701,164
1,122
3.36
3.4
21220
Target:
Actual :
0.24
Hl/Hl
0.24
Hl/Hl

6.10 month
37.43 month
Full FY Saving
x1000'VND
USD
PLANNED SAVING
27,994
1,319
ACTUAL SAVING
30,638
1,444
YTD Saving
x1000'VND
USD
PLANNED SAVING
171,786
8,095
ACTUAL SAVING
188,015
8,860
55,069
60,272
Starting Point:
Average water consumption of NH3 Evaporative Condenser quite high 0.31 Hl/Hl
Target:
water consumption of NH3 Evaporative Condenser is 0.24 Hl/Hl
Trigger Point
water consumption of NH3 Evaporative Condenser is 0.24 Hl/Hl
TIEN GIANG
HOME
SAVING CALCULATION
PLANNED SAVING
= (a-b)*V1*P1/1000)
ACTUAL SAVING
= (a-c)*V2*P2/1000
Calculated data
dd/mm/yy
dd/mm/yy
Hl
Auto updated data

Water YTD
FY ran over :
Cost per Hl YTD :
495,866
4.24
43.0
1,228
VND/Hl Water
Hl/Hl
Hl/Hl
VND
138,381
x1000'VND
PLANNED SAVING
(31,468)
(1,483)
FORSEEN SAVING
(149,540)
(7,047)
x1000'VND
s 0.24 Hl/Hl
USD
PLANNED SAVING
(112,761)
(5,314)
ACTUAL SAVING
(535,853)
(25,252)
ndenser quite high 0.31 Hl/Hl
s 0.24 Hl/Hl
USD
[x1000'VND]
[x1000'VND]
495,866 Hl
4.24
Hl/Hl
43.0
month
ted data)
1,228 VND/Hl Water

138,381 Hl
(1,483)
(7,047)
lculated data)
(5,314)
(25,252)
PLANT :
ELECTRICITY SAVING CALCULATION

FY :
2012/2013
FORMULAS
Starting point :
Target :
Actual :
Cost per KWh YTD:
a
b
c
V1
V2
P1
P2
KWh/hl
KWh/hl
KWh/hl
Hl
Hl
VND/Hl
VND/Hl
Input data
BUDGET FIGURES
Input data
Start FY date :
End FY date :
1-Jan-13
31-Dec-13

Electricity last FY :
Target FY :
Exchange rate:
1USD =
SAVING CALCULATION
Starting point:
15-Mar-13
3.82
dd/mm/yy
KWh/hl
701,164
984
7.74
7.7
21220
Target:
Actual :
3.41
KWh/hl
3.41
KWh/hl

10
month
41
month
Full FY Saving
x1000'VND
USD
PLANNED SAVING
228,652
10,775
ACTUAL SAVING
242,137
11,411
YTD Saving
x1000'VND
PLANNED SAVING
ACTUAL SAVING
282,869
USD
967,254
45,582
1,024,299
48,270
299,551
Electricity consumption at cooling plant over target 2 month (Oct-Nov/2012) Ave 3.82 kw
Electricity consumption at cooling plant archive target 3.41 kwh/hl pro (reduce 0.41 kwh
Increase COP of chilled water system from 2.35 to 2.53
Increase COP of alcohol water system from 1.86 to 2.87
TIEN GIANG
TION
HOME
SAVING CALCULATION
PLANNED SAVING
= (a-b)*V1*P1/1000)
ACTUAL SAVING
= (a-c)*V2*P2/1000
Calculated data
dd/mm/yy
dd/mm/yy
Hl
Auto updated data

Electricity YTD :
FY ran over :
Cost per KWh YTD :
495,866
9.56
43.0
1,042
VND/KWh
KWH/hl
KWH/hl
VND
138,381
x1000'VND
27,597
PLANNED SAVING
FORSEEN SAVING
USD
1,301
(262,432)
(12,367)
x1000'VND
PLANNED SAVING
ACTUAL SAVING
(Oct-Nov/2012) Ave 3.82 kwh/hl product
kwh/hl pro (reduce 0.41 kwh/hl product)
USD
98,889
(940,380)
4,660
(44,316)
[x1000'VND]
[x1000'VND]
495,866 Hl
9.56
KWh/Hl
43.0
month
ted data)
1,042 VND/KWh
138,381 Hl
1,301
(12,367)
lculated data)
4,660
(44,316)
PLANT :

FY :
2012/2013
FORMULAS
Starting point :
Target :
Actual :
Cost per DThr :
Exchange rate :
Starting point :
Target :
Actual :
Cost per DThr :
Exchange rate :
1USD =
1USD =
a
b
c
P
R
a
b
c
E1
E2
P
R
min/month
min/month
min/month
USD/DThr
VND
%OPI
% OPI
%OPI
Min
Min
USD/DThr
VND
Input data
BUDGET FIGURES
Input data
Start FY date :
End FY date :
Cost per DThr :
OPI NONA target :
Exchange rate:
1USD =
1-Jan-13
31-Dec-13
389,170
123.31
83.8
85
21220
SAVING CALCULATION
Starting point:
Target:
Actual :
31-Aug-13
dd/mm/yy
151.00 min/month
50.00 min/month
50.00 min/month

4.07 month
35.40 month
Full FY Saving
x1000'VND
USD
PLANNED SAVING
17,912
844
ACTUAL SAVING
17,912
844
YTD Saving
x1000'VND
USD
PLANNED SAVING
155,922
7,348
ACTUAL SAVING
155,922
7,348
2,490.80

-Lessen OPI Nona loss by Man & Method t 0.81% gim 0.3% / thng, tn sut Man & M
-Starting point : 1.0
-Target : 2.2
-Gap : 1.2
TIEN GIANG
HOME
SAVING
PLANNED SAVING
= (a-b)*12*R*P/(60*1000)
ACTUAL SAVING
= (a-c)*12*R*P/(60*1000)
SAVING
PLANNED SAVING
= (a-b)/100*E1*P*R/(60*1000)
ACTUAL SAVING
= (a-c)/100*E2*P*R/(60*1000)
Calculated data
dd/mm/yy
dd/mm/yy
Auto updated data

OPI NONA YTD :
FY ran over :
184,805
69.2
43.0
min
USD/hr
%
%
VND
51,573
KPI - Full FY
x1000'VND
PLANNED SAVING
203,658
FORESEEN SAVING
(328,368)
USD
9,597
(15,474)
x1000'VND
PLANNED SAVING
ACTUAL SAVING
729,776
(1,176,651)
% / thng, tn sut Man & Method t 6(151 pht)/thng gim 2(50pht)/thng.
USD
34,391
(55,450)
60*1000)
[x1000'VND]
60*1000)
[x1000'VND]
R/(60*1000)
[x1000'VND]
R/(60*1000)
[x1000'VND]
184,805 Min
69.2
43.0
month
51,573 Min
ted data)
9,597
(15,474)
lculated data)
34,391
(55,450)

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Saving Template 2013

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VIETNAM BREWERY LTD.

PLANT : TIEN GIANG

SAVING CALCULATION SYSTEM

Prepared by : Tran Thanh Tuan - TPMC VBLH

Tran Thanh Tuan - TPMC VBLHCM

VIETNAM BREWERY LTD.

ONE WAY MATERIAL LOSS SAVING

Volume can produced target :

Volume can produced actual :

Empty can price budget :

Empty can price actual :

Volume can produced target:

# of month the project contributes to full FY

Tiger - Can 330ml - Carton

Bottles/Cans received at depalletiser

Bottles/ Cans cases returned

Bottles/Cans received by production

Counter inlet can depalletizer

ECI total rej

Difference from Depalletizer to filler

Dirty (conv. #1) rejects

0 Counter inlet ECI

Return to bot. Washer

Loss from ECI to filler (not in clude ECI rejects)

Dirty return to empty store

585 Counter inlet Filler

585 Counter outlet Filler (FHI good prod)

Difference from Filler to FHI (+Lab)

772 Counter FHI No.1 (good prod.)

772 Counter FHI No.2 (good prod.)

0 Total good prod. By both of F.H.Is

Difference FHI to Palletizer

Total rejects by Taptones

Total can loss (Inlet-Outlet)

Prepared by : Tran Tha

* YTD Saving ( to be used for saving of gap to be filled calculation )

Auto updated data

Volume can produced foreseen :

Saving (calculated data)

KPI - YTD Saving contribution (Calculated data)

setting too tight

PERFORMANCE REPORT week

repared by : Tran Thanh Tuan - TPMC VBLHCM

VIETNAM BREWERY LTD.

EXTRACT LOSS SAVING CALCULATION

Volume produced target :

Volume produced actual :

Brewing var cost budget:

Brewing var cost YTD:

Volume Tiger produced target:

# of month the project contributes to full FY

Prepared by : Tran Tha

Auto updated data

Volume produced foreseen :

KPI - Full FY Saving (calculated data)

KPI - YTD Saving contribution (Calculated data)

repared by : Tran Thanh Tuan - TPMC VBLHCM

VIETNAM BREWERY LTD.