PowerPoint Presentation

[Audio] Good day. We are from the Biscuit Plant and we are presenting our Best Practice Session. Project Title: Project WIRE: Wireband In-House Repair and Enhancement Program This initiative aims to repair and replace the SV Oven wireband in-house in order to reduce costs and enhance the technical skills of equipment owners..

[Audio] The Team Wireband warriors were comprise of maintenance and production team.

[Audio] And here is the agenda of this presentation Frist is the Background of the Project The OKR Planning of Activities Execution of the programs The Results And lastly is whats next?.

[Audio] On November 11, 2024, at around 2330H, a power fluctuation caused all machines in the Biscuit Plant to stop. When power was restored, the oven main drive failed to restart, resulting in biscuit buildup and misalignment. This condition led to a fire inside the oven, which was contained by 2400H, but caused significant damage to the wireband..

[Audio] The worn-out wireband negatively affected line efficiency, with SV OEE at only 84% YTD versus the 89% target. From January to October, this resulted in a ₱560,000 Direct Labor variance due to speed losses caused by operating only 18 out of 20 lanes..

[Audio] With that, we developed our OKRs with the objectives of reducing wireband costs through in-house installation and repair, ensuring safe and reliable operation, improving production performance and equipment effectiveness, and increasing labor efficiency. Through in-house wireband repair and commissioning, the project restored safe operation, recovered the SV Line's OEE, improved direct labor efficiency, and eliminated outsourced repair costs..

[Audio] For our planned activities, we first waited for the delivery of the CAPEX-approved wireband, then set the installation date and coordinated the schedule with the Bakery Planner. The team carefully removed the existing wireband, installed and aligned the new one, and conducted post-installation testing to ensure stable performance and optimal production flow..

[Audio] The installation dates were scheduled from October 20 to 25, as agreed upon by the Plant, Maintenance team, and Planner, following the arrival of the CAPEX-approved wireband..

[Audio] Next is the wireband removal and installation. The existing wireband is carefully and safely removed from the drive and return rollers to prevent damage to the oven and surrounding components. After removal, the rollers, drive system, and guide components are inspected for any signs of wear or damage. The oven and related components are then thoroughly cleaned and prepared for the installation of the new wireband to ensure proper alignment and reliable operation..

[Audio] The next activity is the installation, alignment, and testing of the new wireband. This involves carefully installing the new wireband onto the oven rollers, ensuring proper alignment, correct tension, and secure attachment to support safe and stable operation..

[Audio] Lastly, post-installation testing and stabilization runs are conducted to validate equipment performance through trial runs, monitor wireband tracking stability, and make necessary fine adjustments to ensure optimal production flow..

[Audio] As a result, the team was able to save at least four hundred thousand pesos by performing the replacement in-house instead of hiring a third-party contractor, and an additional one hundred twenty six thousand pesos from reduced wireband costs after a few weeks of operation due to the extended service life..

[Audio] Next is the OEE Improvement After the installation of the new wireband, the SV Line's OEE improved to 89.48% from the 85.28% YTD average, reflecting enhanced production stability and efficiency. The line was able to operate at full capacity, restoring all 20 lanes and reducing speed losses..

[Audio] We are able to also to improve our kilograms per manhour increasing from the previous average of 15.83 to 18.5 our kilograms per manhour this November This improvement reflects the positive impact of the newly installed wireband and the restoration of full 20-lane capacity..

[Audio] Direct labor costs improved significantly, dropping from a previous monthly average of fifty-eight thousand pesos to favorable thirty-eight thousand pesos in November, reflecting the positive impact of restoring the line's full capacity through the new wireband installation. With all twenty lanes now operational, manpower utilization is more efficient, resulting in better cost efficiency and improved labor productivity..

[Audio] We also took the initiative to gather feedback from all the operators following the successful achievement. They emphasized the importance of teamwork and acknowledged the leadership's guidance and support throughout the project. Many shared that the collaborative effort and clear communication not only boosted morale but also strengthened their confidence in handling similar tasks in the future..

[Audio] Aside from the operators, we also gathered feedback from the Maintenance team. They likewise emphasized the importance of cooperation and teamwork between departments, highlighting how clear communication and joint efforts were key to the successful completion of the wireband replacement project. Many expressed that this collaboration improved problem-solving, efficiency, and overall confidence in handling future maintenance activities..

[Audio] Following the successful results, we will continue to strive for excellence by focusing on people development through skill enhancement, emergency response drills, cross-training programs, and Step 2-3 BEC qualification. These initiatives aim to equip all Biscuit Plant operators with advanced skills in wireband handling, preventive maintenance, troubleshooting, and safe equipment operation..

[Audio] We will also conduct monthly checks of the tracking rollers to keep the wireband centered, ensuring smooth operation, reducing wear, and preventing misalignment that could cause speed loss or downtime. Safety features such as burner alarms and an automatic fibra lifter will provide immediate alerts and prevent potential fire incidents if the wireband stops unexpectedly, protecting both the equipment and the biscuits on downstream conveyors..

[Audio] And lastly, we aim to improve process yield by reducing defects and rework, enhance the FGWOP of Base Biscuit to minimize overweight sandwiches, and improve TMC performance of the SV Line. Additionally, we strive to achieve 100% SKU compliance by strictly adhering to production standards, monitoring line performance, and implementing continuous quality checks throughout the process..

[Audio] That's all. Thank you, and we hope you gained valuable insights from our Best Practice at the Bagong Ilog Plant..