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POM102D - Saresa
POM102D - Saresa
ABOUT
US
ABOUT SARESA
ABOUT SARESA
Confectioner
increase in
average retail
3 y 9
price
% growth
*based on data gathered from Euromonitor
THE TARGET MARKET
0 A-C
socioeconomic classes
health conscious
COMPETITION ANALYSIS
38.9%
11.1%
8.4%
5.4%
3.2%
7.9%
confectionery
*based on data gathered from Euromonitor
PRODUC
T DESIGN
LOGO
KEY FEATURE
Aratiles
VARIANTS
VARIANTS
light brown
sweet
smooth
creamy
VARIANTS
dark brown
bittersweet
smooth
creamy
FORMULATION
35g cocoa butter 12.5g cocoa powder
1g soy lecithin
PRODUCT DIMENSIONS
11.6cm
1cm
6.6cm
PACKAGING
foil wrapper
paper wrapper
PACKAGING
PACKAGING
PACKAGING
PACKAGING
PACKAGING
DEMAND
FORECAS
T
TARGET
DISTRIBUTION CHANNELS
97.4%
of chocolate
confectionery sales in
2018 will come from
grocery retailers
42.5 57.5
% %
ANNUAL
DEMAND ESTIMATE
Year Total Market Market Market Milk Dark
Demand Share Chocolate Chocolate
(42.5%) (57.5%)
January 0.95
February 1.12
April 0.89
May 0.92
July 0.93
August 0.96
October 1.03
November 1.06
Q1: Jan to
1.01 88,375 90 982
Mar
Q2: Apr to
0.91 76,925 91 846
Jun
Q3: Jul to
0.95 83,125 92 904
Sep
Q4: Oct to
1.13 98,875 92 1,075
Dec
PROCES
S
DESIGN
KEY PROCESS
selection of
machines
drying oven
mixer
conch
cooling tunnel
packaging machine
MAKE OR BUY
Make Buy
Cocoa Powder
and Butter ✓
Dried Aratiles ✓
Milk and Sugar ✓
KEY PROCESS
production overview
1 drying the aratiles
5 packaging
DETAILED PROCESSES
1 drying the aratiles
DETAILED PROCESSES
making the chocolate
2
mixture
DETAILED PROCESSES
3 placing aratiles and chocolate into
the molds
DETAILED PROCESSES
cooling the chocolate
4
bars
DETAILED PROCESSES
5 packaging
FLOWCHART OF OPERATIONS
arrange place trays
acquire raw
clean aratiles aratiles on inside drying
materials
trays oven
place
deposit dried store dried
ingredients cool dried
aratiles into aratiles in
needed into aratiles
molds containers
mixer
transfer
refine in add chocolate fill chocolate
conche remaining mixture to molds using
machine cocoa butter molding the machine
machine
place bars
pack transfer
through remove bars
chocolate for molds to
packaging from molds
shipment cooling tunnel
machine
SUSTAINABILITY
packaging
Envirotech Waste Recycling, Inc.
production
pig feeds manufacturer
maintenanc
e Technotest
CAPACITY
PLANNING
1,440
bars
production per day
PROCESS
Number of Machines: 1
Number of Workers: 1
PROCESS
mix chocolate ingredients
Chocolate Mixer
Makwell Machinery Co., Ltd.
Number of Machines:1
Number of Workers:1
PROCESS
refine mixture in conching machine
Chocolate Conche Ball Mill
Auris Machinery
Number of Machines:1
Number of Workers:1
PROCESS
deposit dried aratiles into molds
PROCESS
transfer chocolate mixture for
depositing and molding
Chocolate Molding Machine
FUDE
Daily Design Capacity: 2880
bars
Number of Machines:1
Number of Workers:1
PROCESS
place chocolate into cooling tunnel
Cooling Machine
Jizaozuo Newest Machinery. Co.,Ltd
Number of Machines:1
Number of Workers:1
INSPECTION
inspect chocolate bars for
319,992 bars
Number of Machines:1
Number of Workers:1
PROCESS
package chocolate bars
Packaging Machinery
Gaocheng Machinery (Huiyang) Co., Ltd
Number of Machines:1
Number of Workers:1
BOTTLENECK ANALYSIS
49.95 seconds process time per
unit
10 sec
12.5 sec
DRYING
DEPOSITING
COOLING PACKAGING
AND MOLDING
MIXING CONCHING
11.25 sec 6.92sec
Cooling
Tunnel
3,200 bars 80% 2,560 bars 1,440 bars 45% 56%
Packaging 5,200 chocolate bars 80% 4,160 bars 1,440 bars 28% 35%
LOCATION
PLANNING
EVALUATION OF FACTORY
LOCATION
40% rent cost
10% features
15% accessibility
SELECTED LOCATION
41.7m
OFFICE LAYOUT
PARKING LAYOUT
WORK
SYSTEM
S
ORGANIZATIONAL
STRUCTURE
CEO
Operations Marketing
Quality Control
Factory
Foreman
Workers
Maintenance
RECRUITMENT PROCESS
1
review resume
2
interview
3
on-the-spot try out
4
quality checklist
COMPENSATION PACKAGE
Monday to Friday
Office hours
Factory hours9am
7amtoto5pm
4pm
working hours inclusive of
hour-long lunch break
WORKING CONDITIONS
PERSONNEL REQUIRED
workers
8 factory workers
2 maintenance staff
3 drivers
2 security
PERSONNEL REQUIRED
employee
s
1 foreman
1
manager
3 regular employees
PERSONNEL REQUIRED
executive
s
1 CEO
1
head of marketing
1 head of operations
QUALITY
MANAGEMEN
T
QUALITY MANAGEMENT
PHILOSOPHY
fresh is best
sanitation is priority
productivity and
punctuality are
QUALITY CHECKPOINTS
1 2
5 4 3
6 7 8
QUALITY CHECKPOINTS
s
3
measurement
Are the chocolate ingredients
measured properly?
s
Were the aratiles distributed properly
4
dispensin
into the molds?
molding
6
coolin
Did the chocolate bars cool properly?
g
Are there unwanted metallic substances
7
metal
present in the chocolate bars?
inspection
Are the chocolate bars packaged properly?
8 Are the labels correct?
Is the quantity per box correct?
packaging
QUALITY CHECKPOINTS
1 2
5 4 3
6 7 8
SUPPLY CHAIN
MANAGEMENT
EVALUATION
OF SUPPLIERS
35% price
5% location
EVALUATION
OF SUPPLIERS
Aratiles
Bapamin Enterprise
Batac City, Ilocos Norte
+639177039618
Php 100.00 per kg
95.74%
EVALUATION
OF SUPPLIERS
Cocoa
Powder
Agro Business
Commodities Trading
NCR, Philippines
+639454374434
Php 20.00 per kg
97.68%
EVALUATION
OF SUPPLIERS
Cocoa
Butter
Wonder bake
G/F, U.P Town Center,
Katipunan Ave, Diliman,
Quezon City, 1108 Metro
Manila
(02) 625-4495
Php 190.00 per kg
97.65%
EVALUATION
OF SUPPLIERS
Coconut
Sugar
Andy Albao Corporation
Unit 301 MJM Bldg, 650 J.P.
Rizal St. Barangay
Valenzuela, Makati City,
Philippines, 1208 Metro
Manila
(02) 831-5175
97.93% Php 370.00 per kg
EVALUATION
OF SUPPLIERS
Milk Powder
Wonder bake
G/F, U.P Town Center,
Katipunan Ave, Diliman,
Quezon City, 1108 Metro
Manila
(02) 625-4495
Php 120.00 per kg
96.96%
EVALUATION
OF SUPPLIERS
Soy Lecithin
96.93%
EVALUATION
OF SUPPLIERS
Foil Wrapper
Best Way General
Merchandising
691 Sto. Cristo St, Binondo,
Manila, Metro Manila
(02) 242-5366
Php 460.00 per roll
96.01%
EVALUATION
OF SUPPLIERS
Paper Wrapper
95.99%
EVALUATION
OF SUPPLIERS
Chocolate
Box
Greenpak Enterprises
45-B Congressional Avenue,
Brgy. Bahay Toro, Quezon
City
(02) 455-7456
Php 21.35 per box
98.41%
EVALUATION
OF SUPPLIERS
Shipment
BoxPhilwyze Packaging
Corporation
753 Quirino Highway,
Novaliches, Quezon City
Metro Manila 1123,
Philippines
(02) 452-2210
96.9% Php 50.00 per box
SUPPLY CHAIN
MANAGEMENT
key
strategies:
1 reliable supply base
2 sourcing strategy
3 risk management
LOGISTICS MANAGEMENT
key
strategies:
1 shipping systems
2 storage
3 distribution
DELIVERY SCHEDULE
Day City
Tuesday Manila
Wednesday Caloocan
Thursday Taguig
Friday Pasig
INVENTORY
MANAGEMEN
T
INVENTORY POLICY
first in
first out
INVENTORY MAINTAINED
raw materials
work-in-progress
finished goods
ECONOMIC ORDER
QUANTITY
Raw Material Unit Annual Demand EOQ* # of Days
Purchases a Between
Year Orders
monthly production
MATERIALS
REQUIREMENT
S
PLANNING
DAILY AND WEEKLY
Raw Materials Inventory Daily Weekly
Quantity Quantity
Raw Material Units
Needed Needed
Paper Wrapper Roll 2,243.59 Rolls 2,243.59 Rolls 2,243.59 Rolls 6,730.77 Rolls
Chocolate Box Box 2,431 Boxes 2,431 Boxes 2,431 Boxes 7,292 Boxes
Paper Wrapper Roll 2,243.59 Rolls 2,243.59 Rolls 2,243.59 Rolls 6,730.77 Rolls
Chocolate Box Box 2,431 Boxes 2,431 Boxes 2,431 Boxes 7,292 Boxes
Paper Wrapper Roll 2,243.59 Rolls 2,243.59 Rolls 2,243.59 Rolls 6,730.77 Rolls
Chocolate Box Box 2,431 Boxes 2,431 Boxes 2,431 Boxes 7,292 Boxes
Paper Wrapper Roll 2,243.59 Rolls 2,243.59 Rolls 2,243.59 Rolls 6,730.77 Rolls
Chocolate Box Box 2,431 Boxes 2,431 Boxes 2,431 Boxes 7,292 Boxes
Renovation of Location
PRE-OPERATIONAL
Tasks October November December
Set up Facilities
Set up Machineries
Training Workers
Test Run
Product Development
DAILY
OPERATION SCHEDULE
Time Cleaning Station Drying Oven Mixer Conche Machine
7:00-7:30
7:30-8:00
8:00-8:30
8:30-9:00
9:00-9:30
9:30-10:00
10:00-10:30
10:30-11:00
11:00-11:30
11:30-12:00
12:00-12:30
12:30-1:00
1:00-1:30
1:30-2:00
DAILY
OPERATION SCHEDULE
Time Depositing and Cooling Tunnel Metal Detector Packaging Machine
Molding Machine
7:00-7:30
7:30-8:00
8:00-8:30
8:30-9:00
9:00-9:30
9:30-10:00
10:00-10:30
10:30-11:00
11:00-11:30
11:30-12:00
12:00-12:30
12:30-1:00
1:00-1:30
QUALITY CONTROL
SCHEDULE
Time Quality Control Person 1 Quality Control Person 2
7:00-7:30
7:30-8:00
8:00-8:30
8:30-9:00
9:00-9:30
9:30-10:00
10:00-10:30
10:30-11:00
11:00-11:30
11:30-12:00
12:00-12:30
12:30-1:00
1:00-1:30
1:30-2:00
2:00-2:30
2:30-3:00
WEEKLY SCHEDULE
7:30-8:00
8:00-8:30 2 1 2 1
8:30-9:00
9:00-9:30 3 2 3 2 1
9:30-10:00
10:00-10:30 4 3 4 3 2 1
10:30-11:00
11:00-11:30 4 4 3 2 1
11:30-12:00
12:00-12:30 4 3 2 1
12:30-1:00
4 3 2
MACHINE WORKFORCE
ASSIGNMENT
Time Cleaning Drying Mixer Conche Depositing Cooling Metal Packaging
Station Oven Machine and Molding Tunnel Detector Machine
Machine
7:00-7:30 Analyn Miguel
8:30-9:00 AnalynRissaFernan
doErnesto
9:30-10:00 AnalynRissaFer
nandoErnestoM
iguel
10:30-11:00
11:30-12:00 Rissa
ErnestoMiguelJose
Daniel
12:30-1:00
WORKFORCE MACHINE
ASSIGNMENT
Time Analyn Rissa Miguel Ernesto Fernando Jose Daniel Stella
10:30-11:00
11:00-11:30 Metal
Detector
11:30-12:00
12:00-12:30 Packaging
SUMMARY OF
WORKFORCE ASSIGNMENT
Cleaning Station Analyn
Drying Oven Rissa
Mixer Miguel
Conche Machine Ernesto
Depositing and Molding Fernando
Machine
Cooling Tunnel Jose
Metal Detector Daniel
Packaging Machine Stella
Quality Control QC Personnel
MAINTENANCE SCHEDULE
workstation
Time
maintenance
Maintenance Personnel 1 Maintenance Personnel 2
6:30-7:00 General Cleaning
7:00-11:00
General Cleaning / /
Cleaning Station / / /
Drying Oven / / /
Mixer / / /
Conche Machine / / /
Cost Category
Cost Category
304,254 one
bars
350,000 bars expected production in year one
Php
30,425,319.61
Php 35,000,000 expected sales in year one
BREAKEVEN ANALYSIS
payback
= 1+ (9,881,052.66/7,066,083.10)
Total Assets Php 19,025,795.30 Php 17,437,162.80 Php 15,848,530.30 Php 14,242,049.90
Total Liabilities and Equity Php 19,025,795.30 Php 17,437,162.80 Php 15,848,530.30 Php 14,242,049.90
BACK-UP
SLIDES
BUSINESS MODEL CANVAS
HOUSE OF QUALITY
PACKAGING
SPECIFICATIONS
1 12 87 1,044
2 24 49 1,176
3 36 31 1,116
4 48 20 960
5 60 9 540
6 72 2 144
Population of 25-50 year old People Belonging to Classes A-C Who are Willing to Buy 4,054,147
Milk and Disadvantage: · Additional costs in investing in dairy farms Advantage: · More ✓
Sugar and coconut plantations convenient
· Machinery heavy · Quality already proven
· Requires more space due to brand familiarity
· Time consuming Disadvantage: · Chance of
choosing a wrong supplier
· No control over cost (e.g.
increase in the price entails
having to change the costing)
LOCATION MEMBER SCORES
Factor Shania Adrian Megan Bea Kelly Spencer
Rent or Cost of
area 94 92 94 91 94 93
Proximity from
distributors 97 99 100 99 99 99
Size of area 95 95 95 96 95 95
Features 95 96 95 97 95 95
Accessibility 95 96 100 99 99 98
SUPPLIER RISK
MANAGEMENT
Risk Possible Consequences Solution
Supplier failure to deliver on time 1) Delays in production It will be stated explicitly in the contract that the supplier
2) Scarcity of resources will have to pay for penalty costs each time there is a
3) Number of units produced will not be late delivery. At the same time, a supplier may only
able to reach production level at the right time commit this violation a maximum of five times.
Supplier delivers damaged, unusable, or substandard 1) Scarcity of usable raw materials Saresa, Inc. will inform its suppliers explicitly the
raw materials 2) Expected production level will not be specifications for the raw materials. Furthermore, it will
met be stated in the contract that Saresa, Inc. will have the
3) If substandard raw materials are used right to return any damaged, unusable, or substandard
for production, quality of the company’s finished raw material to the supplier. In order to prevent
goods will be diminished which could give a bad substandard raw materials from entering production,
impression to the company’s customers managers will be given a criteria to base on, when
selecting raw materials for production.
Miscommunication 1) Wrong delivery execution by the supplier The company plans to always be explicit and clear
about its instructions, information, and specifications to
its suppliers. Information before being sent to suppliers
must be proofread.
ECONOMIC ORDER
QUANTITY
Raw Annual Holding
Unit Unit Cost Set-Up Cost EOQ EOQ*
Materials Demand Cost (25%)
Cocoa
g 4.788 6930875 250 1.197 53806.155 54000
Powder
Paper
pc 0.156 27296.5 250 0.039 18707.088 19000
Wrapper
Chocolate
pc 1.7792 29155 250 0.4448 5724.784 5700
box
REORDER POINT
ROP= (P x L) + (P x Lss)
ROP= Lead Time Stock + Safety Stock
Annual Demand: 350,000 units of 100g chocolate bars
3 days lead time for all raw materials
Annual Lead Time Days of Safety
Raw Materials Daily Demand Lead Time Safety Stock Reorder Point
Demand Stock Stock
January
Q1 26 1,066 27,716 27,714
February
23 1,420 32,660 32,676
March
24 1,142 27,408 27,404
April
Q2 24 1,082 25,968 25,950
May
26 1,032 26,832 26,846
June
24 1,106 26,544 26,550
July
Q3 26 1,043 27,118 27,125
August
24 1,167 28,008 27,993
September
25 1,120 28,000 27,990
October
Q4 27 1,113 30,051 30,039
PRODUCT
milk COSTING
chocolate
Cost
Category
Direct Input Cost per Input Cost per
Cost Per Unit Input Per Unit
Indirect Cost Monthly Cost Monthly Units
Materials Unit Unit
Php Php
Aratiles fruit Php 100/ kg 20 g Distribution Php 55,000 29,167 bars
2.00 1.89
Php Php
Cocoa Butter Php 20/ kg 35 g Salaries Php 537,000 29,167 bars
0.756 10.18
Php Php
Cocoa Powder Php 190/ kg 12.5 g Rent Php 250,600 29,167 bars
4.788 8.59
Php Php
Coco Sugar Php 370/ kg 16 g Utilities Php 68,802 29,167 bars
5.92 2.36
Php Php
Milk Powder Php 120/ kg 15.5g Insurance Php 60,000 29,167 bars
1.86 2.06
Php Php
Soy Lecithin Php 146.8/ kg 1g Marketing Php 15,000 29,167 bars
0.1468 0.51
Php P
Packaging Foil Php 460/ roll 0.0007468 roll
0.3435 h
p
Php
Paper Wrapper Php 2 0.07799 roll 2
0.1560 Total Indirect Cost
5
Php1.77
Box Php 21.35/ box box .
92
5
Input Cost per
Direct Labor Monthly Cost Monthly Units 9
Unit
P
Php
PRODUCT
dark COSTING
chocolate
Cost Category Indirect Cost Monthly Cost Monthly Units Input Cost per Unit
Direct Materials Cost Per Unit Input Required Input Cost per Unit Distribution Php 55,000 29,167 bars Php 1.89
Aratiles fruit Php 100/ kg 20 g Php 2.00 Salaries Php 537,000 29,167 bars Php 10.18
Cocoa Butter Php 20/ kg 37.8 g Php 0.756 Rent Php 250,600 29,167 bars Php 8.59
Cocoa Powder Php 190/ kg 25.2 g Php 4.788 Utilities Php 68,802 29,167 bars Php 2.36
Renovation Cost per unit Quantity Total Manager (13) Php 20,000.00 Php 260,000.00
Office Renovation Php 150,000.00 1 Php 150,000.00 Regular Employees (3) Php 18,000.00 Php 54,000.00
Toilet Renovation Php 25,000.00 1 Php 25,000.00 Factory Workers (8) Php 15,000.00 Php 120,000.00
Lightning Php 80.00 17 (office) Php 4,080.00 Maintenance Staff (2) Php 15,000.00 Php 30,000.00
CASH FLOW
Less: COGS
Fixed Assets
Total Assets Php 19,025,795.30 Php 17,437,162.80 Php 15,848,530.30 Php 14,242,049.90
Total Liabilities and Equity Php 19,025,795.30 Php 17,437,162.80 Php 15,848,530.30 Php 14,242,049.90