ABOUT DABUR EGYPT SYMBIOS & DABUR CELEBRATING 21 MONTH LEAN

PROJECT COMPLETION

On 2nd May 2017 Symbios & Dabur celebrated completion of their

21month LEAN project

Dabur Egypt Entrance into the Egyptian Market is an admirable experience. The company took decision to build the new factory in 10th Ramadan despite of the economic uncertainty back in 2011. Moreover they were clear about their objectives in applying LEAN as follows: Create an operational excellence environment with best industry practices, Deal with complex and dynamic business environment; volume growth, new products etc.. To survive in an ever changing macro-economic conditions, Reduce cost of production through efficiency improvements

Industrial Modernization Center (IMC) Project Manager – Eng. Ashraf Abou

Nasser” opened the closing ceremony recognizing the combined efforts from

Dabur teams and Symbios team led by Eng. Niveen Demerdash as Project

Manager and Eng. Shehab . There has been some suffering along the road

but the results of almost LE 16million savings to date made it a huge success.

Eng. Ashraf Abou Nasser in the closing ceremonial meeting

Dabur Egypt is engaged in the

manufacturing and marketing

of fast moving consumer goods

in Hair Care, Skin Care and

Oral Care categories.

Business is concentrated

mainly in the local Egyptian

market (95% contribution) with

a strategic intent to service all

COMESA markets in the near

future.

Company Currently Employs

Around 400 Workmen and

around 120 Staff, around 98%

Egyptian Nationality.

New Green Field Plant

Commissioned in 2012.

Located in 10th of Ramadan

City

20 Production lines

Constructed over 19000 Sq.m

Area

Certified With ISO GMP 22716

& ISO 9001

Dabur & Symbios Management Team

Mr. Dan Anjan, Dabur Supply Chain Manager commented : “ We were New to LEAN”, at the beginning we were skeptical

that only 21 months would be enough but the project is eye opening on how we operate, the tools we use; how to best use

them. The team has gained “On Hand Experience” that will continue on all production phases. We are proud of what we’ve

accomplished; each objective was presented in the plan, actual action covering all elements. I found bimonthly reviews

essential to keep the momentum of the project and keep people engaged. As part of the contract with Symbios Consulting

and Training, 17 were trained on green belt to perform as coaches training others and ensuring best practices are applied.

Dabur Regional Management Team & Staff engaged in making LEAN Project a Success

Final Review of LEAN 21 Month Project

Journey Insights: The Beginning

Significant Dates and Activities in Dabur Lean Journey –

22nd October 2015

True North and X-Matrix policy deployment workshop was

held on the 22nd of October, 2015. Workshop content were:

• True North & X-Matrix Process Introduction • True North Exercise • Development of a True North Statement • Setting 3-year Objectives • Cascade 3-yr objectives into first year annual objectives • Develop Initiatives by Department to meet the objectives • Consolidation of Objectives + Project Initiatives

Cultural Awareness Workshops: People are the most valuable asset to every organization, Lean embraces active engagement with employees through the Cultural Awareness Workshops.

Lean Green Belt 3-month

training was completed

December 2015. Program

Contents:

• Value to Customer • Value Stream Mapping • Creating Flow • Implementing Pull • Continuous Improvement • Concurrently, LGB

projects have been assigned to the training attendees targeting waste reduction in its various forms.

Eng. Eglal El Hady led the team working on Lean Deployment Wheel

Talk the Lean Language: Translating Concepts of Lean into Arabic made it easier for workers to fully understand them and apply them effectively.

• One of the effective

communication methods used was the posters of Lean translated into Arabic and visible to all plant workers. For Senior Operators they received Lean booklet.

December 2015: With LEAN deployment Dabur and especially through the Cultural Awareness Session identified CA champion and Train Leaders on the Concept of Lean and their role during the Lean Deployment project.

Savings: LE16 Million savings to date. Many saving initiatives launched in all sections of the plant; in

wages, in power consumption, raw material as well as replacing local Egyptian material instead of imported one resulting of significant savings.

High Engagement Level: at all phases of the project and Project Managers exerted an excellent effort in delivering the meaning of Lean to their team members.

• Plant-wide Kick-Off Event

• Prepare periodical events to brief all employees on progress of the lean deployment project

• Lean Green Belt Training

• Lean Black Belt Training

• Setting of the Organization’s True North, strategic goals and initiatives to achieve these goals

Communication and Engagement are key elements in 20 Keys Lean Journey from the start through the Multi level meetings, sports day etc..

Engagement maintained from the kick off meeting through the several workshops and trainings in addition to the Sports Day and workers Annual Day in August 2016

Plant Management communicates organizational objectives with all employees – April 2017

Measure employee satisfaction Survey in April 2017

Dabur Regional Management Team with 10th Ramdan plant workers and operators

Lean guarantees realizing positive results from the minute of implementation which itself motivate workers to do more and come up with ideas increasing production and reducing WASTE.

Visual Posters are useful tool to show objectives for

each Mini Business Unit, roles and responsibilities as

well as showing production levels against the plan.

Good MBU Manager/Coach ensures alignment of MBU

goals to the company as key an eye on WASTE

reduction efforts within his designated MBU. Dabur

Lean Team was well trained and managed to play their

role effectively.

Monthly Awarding for Highest Team Achievement

The closing Ceremony – 2nd May 2017 Symbios role in Lean Deployment Project is completed, however the journey continues and we are expecting greater results from Dabur Egypt applying Lean.