1 1 1 • Overview of Jubilant Bhartia Group 2 • Overview of Jubilant Industries Ltd. Contents Contents 2 3 • Overview of Jubilant Gajraula 4 • Case Study Jubilant Bhartia Group - Snapshot Jubilant Bhartia Group - Snapshot Pharma & Life Sciences Integrated pharma & life sciences player providing products and services to global life sciences companies Revenues FY2010: Leading player in Agri and Performance Polymers sectors Revenue FY 2010: US $ 90 Mn (R 4 200 M ) Food Jubilant FoodWorks- a master franchise of Dominos Pizza in India, Sri Lanka, Bangladesh and Nepal Portfolio of 10 blocks in India and 1 block in Australia and 3 in Yemen Producing Asset – Kharsang Aerospace Exclusive representative for sales & marketing of Bell Helicopters and represents other international aerospace companies. Agri & Performance Polymers Food & Retail Oil & Gas Services 3 Jubilant Bhartia Group : Valued over US$ 3Bn Employs 20,000 people across the globe with 1400 in North America • Jubilant Bhartia Foundation, a not for profit organisation is a social arm of Jubilant Bhartia Group • The foundation is engaged in community development work focusing on primary education, basic healthcare, skill development through vocational training for youth & women • Aims at long term sustainable social intervention by empowering communities through 4P model (Public- Private-People-Partnership) Revenues FY2010: US $ 723 Mn (Rs. 33,620 Mn) (Rs. 4,200 Mn) Revenues: FY 2010: US$ 91 Mn (Rs. 4,239 Mn) Retail Jubilant Retail business with 4 hypermarket cum malls in Bangalore, India Jubilant MotorWorks – sales and service of Audi make cars in Karnataka and Tamil Nadu Development Asset - KG block Oil & Gas Services Consultant to Transocean- offshore drilling company, for Marketing, Technical, Commercial, Legal and Operational areas. Manning and Marketing services for Tidewater Marine International etc Our Vision, Promise & Values Our Vision, Promise & Values Our Values Jubilant Bhartia Group - Global Presence Jubilant Bhartia Group - Global Presence Present in India, North America, Europe and China International sales in more than 65 countries Employs over 5700 people including 1200+ in R&D and over1400+ in North America Roorkee, Uttarakhand UKMHRA approved facility for generics Roorkee, Uttarakhand UKMHRA approved facility for generics Corporate Office & R&D Centres Corporate Office & R&D Centres Kirkland, Quebec, Canada USFDA approved facility for contract manufacturing of Sterile injectables & Non Sterile products and RadioPharma Kirkland, Quebec, Canada USFDA approved facility for contract manufacturing of Sterile injectables & Non Sterile products and RadioPharma Spokane, Washington, USA USFDA approved facility for contract manufacturing of Sterile injectables & Non Sterile products and Allergenic Extracts Spokane, Washington, USA USFDA approved facility for contract manufacturing of Sterile injectables & Non Sterile products and Allergenic Extracts Regulatory & Generic Marketing Regulatory & Generic Marketing Shanghai, China Marketing Office Shanghai, China Marketing Office Corporate Office and R&D Centres in Noida, India Discovery Centre in Bangalore, India 7 manufacturing facilities in India and 3 in North America Dussseldorf, Germany Jubilant Clinsys, Europe office Dussseldorf, Germany Jubilant Clinsys, Europe office 5 Largest integrated pyridine & its derivatives facility in the world Largest integrated pyridine & its derivatives facility in the world Ambarnath, Maharashtra Exclusive Synthesis - Pyridine derivatives Ambarnath, Maharashtra Exclusive Synthesis - Pyridine derivatives Bangalore, Karnataka State-of-art Discovery Centre Bangalore, Karnataka State-of-art Discovery Centre Samlaya, Gujarat Animal Nutrition Products Samlaya, Gujarat Animal Nutrition Products Nira, Maharashtra Life Sciences Chemicals Nira, Maharashtra Life Sciences Chemicals Bharuch, Gujarat SEZ for Vitamins and Life Science derivatives Bharuch, Gujarat SEZ for Vitamins and Life Science derivatives Nanjangud, Karnataka USFDA, AFSSAPS & PDMA approval API manufacturing facility Nanjangud, Karnataka USFDA, AFSSAPS & PDMA approval API manufacturing facility Salisbury, Maryland, USA USFDA approved facility for generics Salisbury, Maryland, USA USFDA approved facility for generics Bedminster, New Jersey, USA Clinical Research Centre Jubilant Life Sciences - Marketing Office Bedminster, New Jersey, USA Clinical Research Centre Jubilant Life Sciences - Marketing Office Corporate Office Branch Offices Manufacturing Facilities R&D Facilities Indian Subsidiaries International Subsidiaries Pune Hyderabad Chennai Lucknow Note: This illustration is not exhaustive. This illustration is not to scale Jubilant Industries – Overview Jubilant Industries – Overview • Amongst Top 3 brands in India for Single Super Phosphate fertilizer and a significant agro nutrient player. • No.1 in India and globally No. 2 for PVA in solid form for chewing gum base . 6 • No.1 in India and amongst the top 3 players globally for Vinyl Pyridine Latex for automobile tyres and conveyor belt. • Consumer brand “Jivanjor” is the 2nd largest brand in India in consumer adhesives and a significant player in the Indian wood finishes market. • Major player in the industrial adhesives market in India catering to PSA, packaging, lamination and other specialized applications Pioneer Company of Agri and Performance Polymers business
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1
1• Overview of Jubilant Bhartia Group
2• Overview of Jubilant Industries Ltd.
ContentsContents
2
3• Overview of Jubilant Gajraula
4• Case Study
Jubilant Bhartia Group - SnapshotJubilant Bhartia Group - Snapshot
Pharma &Life Sciences
Integrated pharma & lifesciences player providing products and services to global life sciences companies
Revenues FY2010:
Leading player in Agri and Performance Polymers sectors
Revenue FY 2010:US $ 90 Mn(R 4 200 M )
Food
Jubilant FoodWorks- a master franchise of Dominos Pizza in India, Sri Lanka, Bangladesh and Nepal
Portfolio of 10 blocks in India and 1 block in Australia and 3 in Yemen
Producing Asset –Kharsang
AerospaceExclusive representative for sales & marketing of Bell Helicopters and represents other international aerospace companies.
Jubilant Bhartia Group : Valued over US$ 3BnEmploys 20,000 people across the globe with 1400 in North America
• Jubilant Bhartia Foundation, a not for profit organisation is a social arm of Jubilant Bhartia Group • The foundation is engaged in community development work focusing on primary education, basic healthcare,
skill development through vocational training for youth & women• Aims at long term sustainable social intervention by empowering communities through 4P model (Public-
a) Chewing Gum is a product for youngstersb) To chew gum in public is criticizedc) Gum residues pollute the environment
Modern Thinking:-
a) To chew gum is funb) Chewing gum contributes to dental carec) Chewing gum regulates the pH-values
Business need for improvementBusiness need for improvement
Chewing gum is fastest growing segment in confectionery industry & growing at a rate of 4-5 %, globally Asian,and under development countries growth is estimated to be 9-10%. New modern thinking has madechewing gum a “Vehicle” to improve nutrition and health despite being a fun product. Today chewinggum has taken an important role of mouth fresheners due to its unique properties of holding flavorsfor a quite long duration.
Business Challenge is to growing demand within optimum cost as majority of market is governed by unorganized local players.
Challenge was to sustain quality
leadership position within optimum
cost levels.
Improvement Journey started
4672
5098
5692
9000
10008
0
2000
4000
6000
8000
10000
12000
2008-09 2009-10 2010-11 2011-12 2012-13
Improvement Accomplished
3
Business need for improvementBusiness need for improvement
The Capacity Model enables to streamline the improvement Journery in two aspects: 1. Throughput rate in Polymerization & Stripping2. Downtime Reduction in Pastillation
Production Capacity Enhancement
To increase Productivity of Polymerization
To reduce downtime in Pastillation
To increase Batch Size of Polymerization
To reduce Batch Cycle Time of Stripping
To reduce downtime of GALA Pastillation System
To reduce downtime of Rotoformer Pastillation System
PROJECT 1: To increase Productivity of SPVA by improving batch sizein polymerization & reduction in BCT in Stripping. ( 644 TPM to 750 TPM)
PROJECT 2 T i OEE f SPVA P d i i R fPROJECT 2: To increase OEE of SPVA Production in Rotoformersection from 78 % to 83% (Production loss reduction by 15 TPM )
PROJECT 3: To increase OPE of SPVA Production in GALA Pastillation from 58 % up to 85 % ( Production Capacity from 750 MT/Month to 900 MT/Month)
PROJECT 1:
To increase Productivity of SPVA by improving batch size in polymerization & reduction in BCT in Stripping. (644 TPM to 750 TPM)
PROBLEM CATEGORY CORRECTIVE ACTION
Back pressure in polymerizationreactor results in further increaseof batch size.
Machine • Vapour line increased from 6’’ to 10’’resulted in increased batch size by 10%.
Stripping cycle time Method Feed charging & heating made parallel Reduction in inspection time Optimization of stripping steps
Productivity Enhancement Action Plan
(atmospheric & vacuum) with outaffecting manufacturing norms.Cycle time reduced from 823 minutes to660 minutes
Increase in ATFE throughput rate Machine • Increase in polymer drying temperatureby increasing steam pressure.Throughput rate increased from 500Kg/Hr. to 700 Kg./Hr.
Modification in Polymerization & Stripping ReactorModification in Polymerization & Stripping Reactor
10” 6”
Productivity Enhancement Action Plan
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PROJECT 2:
To increase OEE of SPVA Production in Rotoformer sectionfrom 78 % to 83 % (Production loss reduction by 15 TPM )
OPE : Productivity X Availability X QualityOPE : Productivity X Availability X Quality
The Power of OPE : The Power of ProliferationThe Power of OPE : The Power of Proliferation
Tons/Annum 7727 10692 2965
Particulars UOM Baseline Status
Post Impl. Status
Gain
SPVA Prod Rate TPD 24 33 9
SPVA OPE Improvement : Performance at a Glance
S od ate 33 9GALA Process OPE % 58 86 28Rotoformer OPE % 78 82 4Monthly Prod TPM 644 891 247Annual Prod Envisaged TPA 7727 10692 2965Monetory Gain on Increased OPE 593 Rs in Lacs
COST REDUCTION DUE TO OPE IMPROVEMENTIMPROVEMENT
500
600
700
800
T
Power Consumption Norms
Results: Specific Power Consumption NormsResults: Specific Power Consumption Norms
GALA - Reduction in Rejection % GALA - Reduction in Rejection %
Ob.-1 : Agglomeration of product during storage
Ob.-2 : Number of start up.15
20
25
23
Rejection %
Modification coldModification of coldair chilling coil forauto drain
In-process Rejection Due to Agglomeration
Observations Corrective Action
Ob.-3 : Shape of pallets.
0
5
10
2010-11 2011-12
0
autoauto drain
Down stream afterFBD
Root Cause
• Relative Humidity of air• Improper grooving in die plate• Cutter RPM
BEFORE AFTER
Reduction in Production Downtime – GALA FRSReduction in Production Downtime – GALA FRS
FRS was chocked with polymer fines. FRS mounted on FBD under vibrationmode.
Way Forward… To get consistent OPE following are the initiatives:
• An Agitated Thin Film Evaporator (ATFE) has been ordered. (Expectedto install by March’ 12)
• Two Heat Exchangers has been ordered. (Expected to install byMarch’12)
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• Proposal for de-humidifier has been raised through CAPEX
• A control chart has been prepared with responsibilities forperiodically verification
Corporate SustainabilityCorporate Sustainability
Green Jubilant Safe Jubilant Responsible Jubilant
Environmental initiatives focused on:
Energy and water conservation by use of bio-fuels
Safety at work prime focus area
International safety standards are practiced
Quarterly assessments and
Committed to serve the society through products and services while maintaining harmony with the Environment
Social Interventions directed at empowering communities through :
Our Approach to sustainable development focuses on the triple bottom lines of Economic, Environment and Social performance
Our Approach to sustainable development focuses on the triple bottom lines of Economic, Environment and Social performance
Our Initiatives are directed towardsOur Initiatives are directed towards
Reduction in greenhouse gas emissions and carbon footprint
Reduction of fresh water consumption and effluent treatment with minimal discharge
Quarterly assessments and reviews help to draw action plans for continuous improvements
Supporting govt. rural Primary Education
Strengthening Basic Healthcare facilities with a focus on Mother & Child
Improving employability of women & youth through skill development
Partnerships with WHO, UNDP and NGOs
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Corporate Sustainability Report published every year as per Global Reporting Initiative (GRI) guidelines and it is audited by Ernst & Young
Rated A+ for 4 consecutive years by GRI
miles & miles to go ………….miles & miles to go ………….C ti l I t N E dC ti l I t N E d………….. Continual Improvement Never Ends………….. Continual Improvement Never Ends