Enjoy Manufacturing Report July 2010

1 – Enjoy Plant Headcount 2 – Salary Cost / ton 3 – Actual Industrial Expenses Vs Budget 4 – Raw Milk Received 5 – Qty in Ton 2010 Vs 2009 A – Tetra pak B – Glass Juice C – Yogurt 6 – Cost Control Project A – Filling M/cs Efficiency & utilization B – Power consumption C – Spare Parts D – CIP E – Wastage 7 – New Project 8 – QC Report – Returns 9 – Pending works

Adminstration Production Engineering QC Warehouses Total Casual0

50

100

150

200

250

300

350

400

450

47

135

62 6181

386

139

44

130

46 5173

344

123

46

142

42 5072

352

144

55

154

44 5479

386

223

54

155

4453

81

387

177

2009 Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10 Jul-10

1 – Enjoy Plant Headcount

1 – Casual staff was 141 which is less last month by 36 persons Vs 120 as a target2 – Regarding staff turn over status during this month, in/out = 22 employed / 2 resigned - YTD in/out = 70/303 – Administration staff increase by 11 than last month

Jan.10 Feb.10 Mar-10 Apr-10 May-10 Jun-10 July10 Total0

20

40

60

80

100

120

140

160

180

200

186 176 147 141 131 128 107 141

122

170

146136

122131

139 137

13 12 13 14 13 12 12 13

budget Cost / ton Actual Cost/ton Tons / one labor

2 – Salary Cost / ton

1 – The total over time for July = 97 768 which represent 12.5 % of total salary 2 – Labour salary = 139 L.E. / ton During this month

3 – Actual Industrial Expenses Vs Budget

B1Jan-10 B1Feb-10 B1Mar-10 B1Apr-10 B1May-10 B1Jun-10 B1Jul-10 B1Aug-10 B1Sep-10 B1Oct-10 B1Nov-10 B1Dec-10-500,000

0

500,000

1,000,000

1,500,000

2,000,000

2,500,000

3,000,000

3,500,000

4,000,000

4,500,0002,

723,

609

2,66

0,70

0

2,92

6,65

2

3,32

5,51

1

3,41

4,91

7

3,42

0,10

8

3,78

7,08

6

4,20

6,30

6

4,01

6,75

9

3,73

6,72

4

3,49

4,06

2

3,50

5,72

72,07

9,37

7

2,41

2,54

3

2,59

0,85

6

2,47

3,18

9

2,87

3,06

0 3,66

0,36

8

3,02

1,39

5

644,

232

248,

157

335,

796 85

2,32

2

541,

857

-240

,260

765,

691

Budget 2010 Actual 2010 Diff. in L.E.

1 – The total Saving YTD is 3 147 795 L.E. and saving during this month was 765 691 L.E.

Expenses in L.E./Ton

Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10 Jul-10 YTD 0.0

50.0

100.0

150.0

200.0

250.0

300.0

350.0

400.0

450.0

500.0

342.5

431.4

388.2359.8

394.3

459.7475.6

408.2

Expenses budget L.E./ton

1 – YT D industrial cost / ton 408 L.E.

B1Jan-10

B1Feb-10

B1Mar-10

B1Apr-10

B1May-10

B1Jun-10

B1Jul-10

B1Aug-10

B1Sep-10

B1Oct-10

B1Nov-10

B1Dec-10

0

500

1,000

1,500

2,000

2,500

3,000

3,500

2,0802,020

2,508

2,877 2,789

2,296 2,288 2,273

2,6182,802 2,892

2,785

2,0151,930

2,142

3,303

2,5242,742

2,210

Plan Actual

4 - Raw Milk Received

1 – YTD, Dina farm supplied = 70 ton /day which represent 89 % of the total milk received2 – YTD, milk received represent 56 % of the annual target3 – the actual milk received during this month is less than target due to having enough stock of finished product

B1Jan-10

B1Feb-10

B1Mar-1

0

B1Apr-10

B1May-10

B1Jun-10

B1Jul-10

B1Aug-10

B1Sep-10

B1Oct-10

B1Nov-10

B1Dec-10

0

2,000

4,000

6,000

8,000

10,000

12,0003,

854 4,59

9

3,85

9

3,66

4 4,46

6

4,96

0

2,50

8

5,17

5

5,15

3

5,33

5

4,92

4

4,76

76,07

1

5,59

2 6,67

4

6,65

7

7,28

6

7,96

3

6,00

0

5,33

9

4,70

2 6,12

2

5,11

4

5,31

5

2009 in ton Plan 2010 in ton Actual 2010 %

5 - Qty in Ton 2010 Vs 2009

1 – YTD, Total Production = 72 835 tons which represent 84 % of the total yearly target2 – the reason for less productivity during last 6 months was due to : A – Long time to receive spare parts and no enough TP staff for technical support B – Utilities break down due to hot season C – High turn over of technical staff and postponed the TP training

Milk 1 L Juice 1 L Milk & Flavoured 200 ml

Juice 200 ml Fino Milk -

500

1,000

1,500

2,000

2,500

3,000

2,3

25

2,3

25

590

2,1

40

695

1,08

2

2,16

1

503

1,63

3

541

1,8

08

1,9

51

438

2,0

69

531

82

5

1,57

9

191

2,58

5

230

Max Capacity in Ton Plan inTon Modified plan in Ton Actual in Ton

5 – A – Tetra pak - Plan Vs Actual Finish Product in Ton

1 – Production of 200 ml reach to 65 % of the max capacity2 – Total TP Production represent 99 % of sales forecast

5 – B – Glass Juice - Plan Vs Actual Production in Ton

Glass 1 L Glass 250 ml x 12 Glass 250 ml x 24 -

100

200

300

400

500

600

700

800

900

450

590

500

297

769

323

505

596

180

356 40

5

186

Max capacity in Ton Plan in Ton Modified plan in Ton Acutal production in Ton

1 - Total Glass Juice Production represent 68 % of the max available capacity and represent 74 % of Modified Sales forecast

5 – C – Yogurt Plan Vs Actual in Ton

Total0

100

200

300

400

500

600

700

800

900

1,000

800

633

931

799

Max capacity in ton Plan 2010 in tonModified plan 2010 in ton Linear (Modified plan 2010 in ton)Actual 2010 in ton

1 - Total Yoghurt Production represent 100% of the max available capacity and represent 126 % of sales forecast as a result of changing target due to market demand

TBA/8 L1 TBA/8 L2 TBA/19 L4 TBA/19 L5 TBA/22 L6 TFA/3 L70

100

200

300

400

500

600

700

800

50

251 230

343280

10845

54171

100

78

623

91

110106

120

23

281

162

119 73

92

520

297

13966 74

12639

Production time Equipment stop Other StopTime outside production phase Idel time

1 - Tetra Fino could not archive the target due to : A – Bottle neck of process equipment B – No need to produce FC milk which should run at the same time with 1 litter m/c 2 – Slim cap for Line #1 should be replaced by recap due to slim cap could not be used for export and Al-Misrieen products and that is one of the reason to limitation of production time

6 – Cost Control Projects A – TP Filling m/cs Working hrs

6 – Cost Control Projects A – Filling M/cs Efficiency

TP L#1-1L TP L#2-1L TP L#3-200ML

TP L#4-200ML

TP L#5-200ML

TP L#6-500ML

TP L#7-200ML

Total TP M/cs

Erica M/c Formaseal M/C

Total Yogurt

m/c

Glass L#1-250 ML

Glass L#1- 1L

Glass L#2- 1 L

Total Glass M/Cs

Total Plant M/Cs

0%10%20%30%40%50%60%70%80%90%

100%

52%

92%80% 80% 82%

98%

78% 74%84% 86% 84%

67%74% 73% 68%

75%

Efficincy %

• Remarks: • Wedge m/cs produced 3 types of product during this month till complete using the package materials

6 – Cost Control Projects B – Power consumption

Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10 Jul-10 YTD0

20406080

100120140160

96 97 103 109 10998

141

107

7180 75 74 74 66

9275

2940

30 31 35 34 40 34

Qty / ton Total power Cost L.E. / ton Cost/1000 packs

• The total standard power cost/ton=55 L.E• The total standard power cost/ 1000 pack=25 L.E

6 – Cost Control Projects) C – Spare Parts

Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10 Jul-10 Total0

10

20

30

40

50

60

70

80

90

78

6358

54

64

54 52

60

28 2723

20

29 2825 26

20 20 20 20 20 20 20 20

spare parts Cost L.E./ ton Actual cost L.E./1000 pack Standard cost L.E./1000 pack

• The total standard spare parts cost/ 1000 pack = 20 L.E And still waiting confirmation from TP Co.

6 – Cost Control Projects D - CIP

Dec-09 Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10 Jul-10 YTD0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

1.91.6

1.3 1.3 1.2 1.2 1.1

1.51.3

3.22.9

2.2 2.3 2.3 2.22.0

2.72.4

Kg Acid / ton product Kg Soda / ton product

6 – E – Wastage in L.E.

TP section Glass section Yogurt section Total0.00%

0.50%

1.00%

1.50%

2.00%

2.50%

3.00%

2.36%

1.60%

1.20%

2.40%

Chart Title

Wastage Value %

7 – New Project ( Cost & Time frame )ID Task Name Fixed Cost

1 New Air Compressor&drayer ج.م. 3,295,161.002 New RO unit ج.م. 135,000.003 New electric power panels ج.م. 65,000.004 Overhauling Generators ج.م. 45,000.005 Upgrade PLC for UHT&recovery tanks ج.م. 600,000.006 Water collection project ج.م. 300,000.007 Al Misrieen drink unit installation ج.م. 35,000.008 Yoghurt Erica mould 80 g ج.م. 50,000.009 Overhauling Erica M/c -20000 service w. hr ج.م. 240,000.0010 Repairing TP conveyor system 60,000.00 .ج.م11 New PLC for Glass CIP unit ج.م. 15,000.0012 Purchasing shrink pallet m/c ج.م. 50,000.0013 Purchasing 5 electric & Diesel forklift ج.م. 650,000.0014 New steam traps & regulating valves ج.م. 60,000.0015 Blow down steel tanks ج.م. 20,000.0016 Repairing wastage treatment water plant daf,diffusers ج.م. 25,000.0017 Government water supply ج.م. 3,000,000.0018 Fire alarm system ج.م. 60,000.0019 Plant Air conditioning system ج.م. 200,000.0020 Civil works-drained room,al-salam store, others ج.م. 75,000.0021 Natural Gas supply- TQA co. ج.م. 0.0022 Cleaning of Softener Resin ج.م. 5,000.0023 Ice bank project ج.م. 1,500,000.0024 Transfer Glass Lines ج.م. 50,000.0025 Government drain line ج.م. 20,000.0026 Overhauling Process equipment ج.م. 200,000.0027 Audit repair for TP DE m/cs ج.م. 180,000.0028 OCR projects ج.م. 300,000.0029 Overhauling Ammoina & air compressors ج.م. 1,100,000.0030 Purchasing 2 printers ج.م. 75,000.00

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8 – QC Report – Returns

• Reason for Sales return qty in Cartons:Product Sales return Qty Due

to bad handling in carton

Sales return Qty Due to Expire date

Manufacturing drained

&reprocessed in carton

Total

Milk 1 L 1 158 172 45 1 375

Flavoured Milk 200 ml 529 204 1 734

Milk Joy 637 174 0 811

Juice 1 L 673 21 40 698

Juice 200 ml 61 4 0 65

Glass 1 L 120 9 0 129

Glass 250 ml 858 38 4 900

Yoghurt ( cups ) 846 2 482 0 3328

Yoghurt ( Gallons – 4 kg ) 277 4 608 0 4 885

Samples and Lab Analysis 1 – All Production was released after QC approval this month 2 – No market complain about taste ( approved recipes ) 3 – 26 costumer complaints during this month , most of them as a result of Recap of one liter 4 – No Spoil ( un-sterility ) during this month

9 – Pending* achieving works Pending Works : 1 – The main issue for Environment project, supply Government water and sewage pipe line ( waiting for fund ) 2 – Repairing Electric generators, synchronization unit and interconnection with new electric room ( waiting for fund ) 3 – Complete overhauling for main pasteurize plant – Waiting TP reply 4 – Install the new RO plant – 15 / 5 / 2010 5 – Install the drink unit received from Al-Misrieen Waiting TP reply 6 – Upgrade of Old flex (UHT) – post bond till arrange between Enjoy and TP 7 – Water collection for all processing equipment – waiting quotations 8 – Fire alarm system ( waiting for fund ) 11 – milk tanker local quotations were received and waiting overseas quotations Achieving Works : 1 – TWF filling m/c start production this month 2 – Boilers overhauling were completed 3 – Spoiling product room was completed with new well and m/c was transferred 4 – More than 3000 wooden pallets were produced from scrape wood 5 – New extension project, waiting final offer after complete technical discussion 6 – Al-Zomer store was completed and ready to sore finish product