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Unilever Pakistan Foods
Ltd.
Consumer Foods Plant
Summer Internship
2007
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Farook Amir
Internship Presentation
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Unilever
Unilever is a $53.43 billion company with a $5.40 billion (10.123%)operating profit (in 2006). Its operations exist in 100 countries with179,000 employees.
It has 400 brands spanning 14 categories of home, personal care
and food products.
Unilever is a share-holder in Unilever Pakistan Limited.
UPL has 42 units across Pakistan (including own & 3P Factories,
Distribution Centres, Offices & Dev. Centres etc.)
Distribution network consists of 400 stockists and 200000 retailers
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Main Brands
Knorr
Lipton
Supreme
Lux Fair & Lovely
Life buoy
Walls
Sunslik
Clear
SURE
AXE
Energile
GlaxoseD
Blue Band
Rafhan
Surf Excel
Wheel Dove
Ponds.
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Consumer Foods Plant, Lahore
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Consumer Foods Plant, Lahore
Consumer Foods factory manufactures 20 different packaged foodproduct categories under 4 brands with 197 active SKUs (91 variants, 47packing styles / sizes).
Knorr (Ketchup, Mayonnaise, Chicken Cubes, Chinese Spices,
Soups, Noodles)
Rafhan (Custard, Jelly, Magic Jelly, Kheer Mix, Firni Mix, Ice-cream Powder, Cornflour )
Energile (Fruit Crystals, Buzz: Energy Drinks)
Glaxose D (Glucose Drink)
Sauces: For McDonalds, KFC, Pizza Hut and otherRestaurants/hotels ( Big Mac Sauce,
Tartar Sauce, Demi-glace Sauce, Chocolate
Sundae topping, Strawberry Topping..)
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Consumer Foods Plant, Lahore
66693 m2 of land. Total built-up area 21187 m2(32%)
No of active recipes 94 (Recipe complexity-157 Tons / recipe)
Maximum LTA free man hours worked so far 5.50 Million (1550 work days)
Utilities include Boilers, Air compressors, Water Turbines, Generators.
100% stand-by power generation.
Capacity-30,000 tons per annum
The lowest quality cost plant amongst UBF, Asia.
No Product recall so far.
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Consumer Foods Plant, Lahore
Quailty Certefications: ISO 9001
ISO 14001 OHSAS 18001
HACCP Certification
UQCSRM Regional Audit A Rating JIPM TPM Excellence Level 1 Award
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Details
Duration: 8 weeks
First 2 weeks: QA/QC
Last 6 weeks: Safety & Engineering
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Project
Management of Change(MOC) Prepare an MOC document for capacity enhancement
projects at the Noodles Building
An MOC document defines the controls andmechanisms to accommodate any change in the
existing process.
A change may be classified as:
a change within existing technology,
a change outside the existing technology,
or a replacement in kind.
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Management of Change
For MOC implementation the concerned
department establishes and implements
written procedures to manage changes to the
process
MOC is a part of the DuPont PSRM
DuPont Behavioural based safety program is a
key part of RBF objectives. It aims to
transform unsafe behaviours into safety
conscious behaviours
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Management of Change (MOC)
Change in process ( raw materials, equipment, process,
technology) potentially invalidate prior hazard assessments
and create new hazards.
Hence existing documented technology must be reviewed
Review: PSI, SOP, PHA/EHA,
Re-assess: SHE impact, Worker skill level
Document: Basis for change, Approval &
Authorization for change, trial results
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Work at RBF
Capital Expenditure Proposals (3) SHE Checklists (6)
TPM activities:
Schedule A Board (SHE pillar)
Schedule B Board
Accident (MTC) Investigation
Autonomous Maintenance (JH)
Safety Kaizens
Preparation of OPL
WWA, WWBLA, PMA
Red-Tagging (5S)
SOPs
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PSI, SOP, MSDS, PHA, EHA, THA, QA, QC,
PSRM, TPM, OHSAS, UQCSRM, WWA, WWBLA,
PMA, SPC, JH, AM, KK, OPL, QDI, HAZOP, 5S,
HACCP, HH, ABC, E&T, SHE, MOC, PDB, EDB,
SOC, SOL, P&ID, UA/UC, FAC, MTC, RWC, LTA
.
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THE END
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