Feed Mill Operations & Key Performance Indicators. Charles Stark North Carolina State University

Transcription

1 Feed Mill Operations & Key Performance Indicators Charles Stark North Carolina State University

2 Major Areas of Responsibilities Production Quality Costs Safety Housekeeping Human Resources Strategic Planning/Cost Analysis

3 Quality Review ingredient and feed sampling program Review quality assurance results Answer phone calls on feed quality complaints Submit FDA medicated feed samples Evaluate standard operating procedures Flushing Sequencing Set the standard for Quality Assurance

4 Production Review daily production records Schedule feed production Schedule ingredient deliveries Schedule employee shifts, vacation, etc Evaluate employee and equipment production

5 Production Daily Checklist Bulk Ingredient Inventory Magnets Bag Ingredient Inventory Lock out Fat Tank Micro bin Inventory Scale checks Drug Reconciliation Feed production Report (Appendix Q) Pellet Mill Reports (2) Maintenance Boiler

6 Cost Prepare annual budget Evaluate time cards, labor and overtime. Review & report monthly costs Personnel, Property, Operating Evaluate new technology to lower manufacturing cost Prepare Capital request

7 Safety New Employee Safety Training Safety Meetings Monthly, Weekly Annual Safety Training Fire Ext, Hot Works, Etc Inspections Housekeeping, Safety Permits Hot Works, Confined Space

8 Housekeeping Interior Process areas (grinding, pelleting, etc) Non-process areas (bin decks) Exterior Landscaping Grass Control Rooms/Offices Mangers office is a reflection of expectations!!!

9 Human Resources Hiring Training Employee Development Continuing Education Mentoring Discipline Conflict Resolution Investigation Safety Grievance

10 Feed Mill Key Performance Indicators Productivity Tons/man hr Changeovers Tons per run Energy per ton Electrical Fuel Actual vs. scheduled hrs Downtime Unplanned vs. planned Transportation efficiency

11 Feed Mill Key Performance Indicators Cost Personnel Salary (exempt) Hourly (non-exempt) Overtime Property cost Repair and maintenance Routine Extra-ordinary Operating Supplies Utilities

12 Feed Mill Key Performance Indicators Quality Samples submitted vs. required Particle size Finished feed nutrient content % Theoretical Moisture Protein Fat Shrink/Gain

13 Feed Mill Key Performance Indicators Safety Days since LTA Days since accident Near misses Safety test results

14 Reports & Charts

15 Weekly reporting Hours Manufacturing Salary 120 Tons 9000 Base 320 Schedule hrs 120 OT 80 Actual hrs 125 Employees Change overs 43 Salary 2 Capacity Hourly 8 R&M Downtime hrs 4 KPI Transportation Tons Shipped 8500 Total Hrs 520 Emergency Outs 7 Hourly 400 Feed Returned 28 Tons/Hr 72 Inventory Tons/Changeover 209 Beginning 1800 Tons/Man Hr 17 Efficiency 90 Ending 2300 Days Since LTA 372 Days Since Accident 45

16 Monthly report Week Total Hrs Base OT Tons Tons/R un Tons/Man Hr , , , , Average , Total 2,265 1, ,100 Days LTA Days Doctor Safety Quiz Shrink

17 Manufacturing costs $/month Actual Budget Difference Personnel Salary 11, Hourly 23, Benefits 10, Property Repair & Maintenance 31, Die & Roll 3, Depreciation 32, Rentals 2, Vehicle Operating Electricity 38, Fuel 63, Water 2, Manufacturing Supplies 2, Office Supplies 1, Waste Other 80, Total $ 302, Tons 35,100 34,000

18 Ingredient Crude Protein Report (SBM) Item Jan Feb Mar Apr May Mean, % Std Dev Mean ½ St Dev Sample number

19 Inventory Trend Report Major Scale

20 Pellet Mill Motor Load hp

21 Shewart Control Chart Used to determine if a process is stable and predictable. Creates a picture of system changes over time. Calculates: Means Lower and Upper Control Limits Out of control processes

22 SPC Process Change Seven points moving in one direction (up or down) Seven points above or below the centerline

23 SPC Process Change Seven points moving in one direction (up or down) Seven points above or below the centerline

24 Example of SPC Chart

25 Run Chart SBM Crude Protein

26 Run Chart Feed Crude Protein

27 Run Chart Feed Crude Protein % Theoretical