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Lanner client Britvic discuss their Leeds factory & warehouse simulation

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The document summarizes a simulation project conducted by Britvic Soft Drinks to model operations at their Leeds factory and warehouse after installing a new high-speed PET production line and expanding warehouse capacity. The simulation aimed to answer questions about vehicle traffic, gate throughput, trailer parking needs, loading bay requirements, forklift needs, and warehouse flows. Key learnings included identifying pinch points in traffic flows and validating the number of trailer parking spaces and loading bays needed. Next steps involve further enhancing the Leeds model with additional production line and automation details and developing models for other Britvic sites.

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Neil Brinkman, David Rice Britvic Soft Drinks Leeds factory & warehouse simulation
Agenda Introductions Introduction to Britvic Simulation overview Project overview Findingssummary
Making lifes everyday moments more enjoyable
Leading branded soft drinks business More than 30 brands More than 30 brands
Strategy Being the benchmark integrated branded soft drinks business for both PepsiCo and our own brands in GB & Ireland Fully exploiting global category opportunities in Kids, Family and Adult Creating a simple focused operating model, empowering our people and matching resource and capability to the opportunities Being a trusted and respected member of the communities in which we operate
Leading branded soft drinks business 贈1,321.9m Group revenue Source: Britvic Plc Annual report 2013
Leading branded soft drinks business 3,300 employees
Leading branded soft drinks business 2,066.9m litres per year Source: Britvic Plc Annual report 2013
Strong track record and growing No2 in British branded carbonate soft drinks in Irish branded soft drinks in French syrups Britvic became PepsiCo bottler in UK No2 No1 1987 Source: Nielsen/Britvic Soft Drinks report 2013
Owned brands in UK Franchised brands in UK
Where we operate - GB Hemel Hempstead Solihull Factories Offices 1850 employees Lutterworth Distribution Norwich 8 lines PET Beckton 4 lines Plastic (PET) Rugby 6 lines Can, PETandAseptic Leeds 3 lines Glass and Bag in box 1 PETline 640 products Where we operate
The simulation challenge
Network simulation: Have the ability to model our network Supporting business decisions Capital investment planning Whats made where Storage requirements Inventory policy review Benefits cases Centre of gravity analysis Capacity planning Having agreed the network solution a more detailed analysis is required by location.
Skyfall Leeds New High Speed PET line New high speed PET production line optimised at 36K bottles per hour New finished goods warehouse New loading bays to support increased inbound materials and outbound loads New trailer park Line capable of producing 1litre to 3 litre packs Line started Monday 9th November
What were the questions? Vehicle movements around the site Gatehouse throughput Trailer parking how many? Loading bays how many? Internal warehouse movements Number of FLTs required Traffic volumes key pinch points Warehouse flows
Leeds - Skyfall New loading bays New warehouse New staff & visitor parking New trailer parking New production Line Existing production lines (3) Gatehouse
Key learnings Vehicle movements around the site Gatehouse throughput Site could work, however we have designed the trailer park to enable easier access Trailer parking how many? 30-35 trailer parking spaces, this is to ensure we cover off weekend pre loading Loading bays how many? 6 loading bays would work Internal warehouse movements Number of FLTs required Confirmed the number FLTs in each area Traffic volumes key pinch points Key H&S risk points identified, 1 way system put in place Warehouse flows Automation flows started to be considered
Beginning to see the output from the modelling One way system out into the loading bayTraffic flows in to the warehouse
Beginning to see the output from the modelling Warehouse starting to take shapeLoading bays nearly ready for use
Simulation key points / next steps : Key learnings : Great way to bring changes to life Key to gain buy in from the sites ensure you can model the as is Be clear on the questions you are seeking to solve Good guidance from Lanner, as we wanted answers to questions that didnt exist!!! Next steps : Further enhancement of the Leeds model Refine the modelling as we understand the operation post go live 2nd new line announced Further automation Development of models for other sites further investment at Rugby site
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Lanner client Britvic discuss their Leeds factory & warehouse simulation

  • 1. Neil Brinkman, David Rice Britvic Soft Drinks Leeds factory & warehouse simulation
  • 2. Agenda Introductions Introduction to Britvic Simulation overview Project overview Findingssummary
  • 3. Making lifes everyday moments more enjoyable
  • 4. Leading branded soft drinks business More than 30 brands More than 30 brands
  • 5. Strategy Being the benchmark integrated branded soft drinks business for both PepsiCo and our own brands in GB & Ireland Fully exploiting global category opportunities in Kids, Family and Adult Creating a simple focused operating model, empowering our people and matching resource and capability to the opportunities Being a trusted and respected member of the communities in which we operate
  • 6. Leading branded soft drinks business 贈1,321.9m Group revenue Source: Britvic Plc Annual report 2013
  • 7. Leading branded soft drinks business 3,300 employees
  • 8. Leading branded soft drinks business 2,066.9m litres per year Source: Britvic Plc Annual report 2013
  • 9. Strong track record and growing No2 in British branded carbonate soft drinks in Irish branded soft drinks in French syrups Britvic became PepsiCo bottler in UK No2 No1 1987 Source: Nielsen/Britvic Soft Drinks report 2013
  • 10. Owned brands in UK Franchised brands in UK
  • 11. Where we operate - GB Hemel Hempstead Solihull Factories Offices 1850 employees Lutterworth Distribution Norwich 8 lines PET Beckton 4 lines Plastic (PET) Rugby 6 lines Can, PETandAseptic Leeds 3 lines Glass and Bag in box 1 PETline 640 products Where we operate
  • 13. Network simulation: Have the ability to model our network Supporting business decisions Capital investment planning Whats made where Storage requirements Inventory policy review Benefits cases Centre of gravity analysis Capacity planning Having agreed the network solution a more detailed analysis is required by location.
  • 14. Skyfall Leeds New High Speed PET line New high speed PET production line optimised at 36K bottles per hour New finished goods warehouse New loading bays to support increased inbound materials and outbound loads New trailer park Line capable of producing 1litre to 3 litre packs Line started Monday 9th November
  • 15. What were the questions? Vehicle movements around the site Gatehouse throughput Trailer parking how many? Loading bays how many? Internal warehouse movements Number of FLTs required Traffic volumes key pinch points Warehouse flows
  • 16. Leeds - Skyfall New loading bays New warehouse New staff & visitor parking New trailer parking New production Line Existing production lines (3) Gatehouse
  • 17. Key learnings Vehicle movements around the site Gatehouse throughput Site could work, however we have designed the trailer park to enable easier access Trailer parking how many? 30-35 trailer parking spaces, this is to ensure we cover off weekend pre loading Loading bays how many? 6 loading bays would work Internal warehouse movements Number of FLTs required Confirmed the number FLTs in each area Traffic volumes key pinch points Key H&S risk points identified, 1 way system put in place Warehouse flows Automation flows started to be considered
  • 18. Beginning to see the output from the modelling One way system out into the loading bayTraffic flows in to the warehouse
  • 19. Beginning to see the output from the modelling Warehouse starting to take shapeLoading bays nearly ready for use
  • 20. Simulation key points / next steps : Key learnings : Great way to bring changes to life Key to gain buy in from the sites ensure you can model the as is Be clear on the questions you are seeking to solve Good guidance from Lanner, as we wanted answers to questions that didnt exist!!! Next steps : Further enhancement of the Leeds model Refine the modelling as we understand the operation post go live 2nd new line announced Further automation Development of models for other sites further investment at Rugby site