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VINCENT MAURICE VP OPERATIONS – DAIRY DIVISION EUROPEAN OPERATIONS RESET MODEL

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Page 1: EUROPEAN OPERATIONS RESET MODEL - danone …danone-danonecom-prod.s3.amazonaws.com/user_upload/Investisse… · Construction of Danone Dairy Production System Work with each plant

VINCENT MAURICE VP OPERATIONS – DAIRY DIVISION

EUROPEAN OPERATIONSRESET MODEL

Page 2: EUROPEAN OPERATIONS RESET MODEL - danone …danone-danonecom-prod.s3.amazonaws.com/user_upload/Investisse… · Construction of Danone Dairy Production System Work with each plant

30%

40%

50%

60%

70%

80%

0

1000

2000

3000

20112010

Volume (kt)

B20141201320122007 2008 2009

Volume Ope. UtilizationOpe. Efficiency

Sustained efforts led to a

better efficiency in plants

But volumes are steadily decreasing since 2010

Resulting in continuous

reduction of capacity

utilization in Europe

Overall asset

utilization (Operational

efficiency x

Operational

utilization)

now below

35%

Note1: B2014 includes a change of scope with 4 plants less in the network, equivalent to 167kt

TOUGH MARKET CONDITIONS ARE IMPACTING THE DAIRY MANUFACTURING ORGANIZATION IN EUROPE…

Page 3: EUROPEAN OPERATIONS RESET MODEL - danone …danone-danonecom-prod.s3.amazonaws.com/user_upload/Investisse… · Construction of Danone Dairy Production System Work with each plant

… RESULTING IN A FRAGMENTED MANUFACTURING FOOTPRINT WITH HIGH COMPLEXITY

Salas

Castello

ParetsTres Cantos

Aldaia

Villecomtal St JustCasale

MolayDPB

Bailleul

Rotselaar

Hagenow

Ochsenfurt

Rosenheim

Budapest

Benesov

Warsaw

Bierun

Bucharest

Sofia

Tenerife

Lunnarp

Sevilla

24 plants in early 2013

Ambitious plan to transform

European Operations

Page 4: EUROPEAN OPERATIONS RESET MODEL - danone …danone-danonecom-prod.s3.amazonaws.com/user_upload/Investisse… · Construction of Danone Dairy Production System Work with each plant

12 plants 2 plants

Significant CAPEX allocated to differentiate our products

through innovative technologies

3 plants

Packaging Process & Packaging Packaging

NEVERTHELESS, WE CONTINUOUSLY CREATE VALUE THROUGH INNOVATION …

KISS OIKOS / DANIO ACTIKIDS / DANONINO

Page 5: EUROPEAN OPERATIONS RESET MODEL - danone …danone-danonecom-prod.s3.amazonaws.com/user_upload/Investisse… · Construction of Danone Dairy Production System Work with each plant

98

99

1

0

96

97

2012

% of CSL

20132011

+1ppt

2010

2.8

3.0

3.2

0.0

0.2

2011

H2O consumption, m3/ton

2010

-6%

2012 2013

619

489

0

200

400

600

800

2007

CO2 consumption

20132009 2010 2011 2012

-21%

2008

… MEANWHILE SIGNIFICANT IMPROVEMENT ON SEVERAL KEY PERFORMANCE FUNDAMENTALS

CUSTOMER SERVICE LEVELWATER CONSUMPTION

(m3/T FG)

CO2 EMISSIONS(G Eq CO2/Kg FG)

Page 6: EUROPEAN OPERATIONS RESET MODEL - danone …danone-danonecom-prod.s3.amazonaws.com/user_upload/Investisse… · Construction of Danone Dairy Production System Work with each plant

01 Integrated Operations

organization

02

03

TO REACH SUPERIOR PERFORMANCE, WE NOW FOCUS ON 3 STREAMS FOR OPERATIONS IN EUROPE

Manufacturing

Competitiveness

Supply Chain

Co-partnerships

Page 7: EUROPEAN OPERATIONS RESET MODEL - danone …danone-danonecom-prod.s3.amazonaws.com/user_upload/Investisse… · Construction of Danone Dairy Production System Work with each plant

INTEGRATED OPERATIONS: A CHANGE OF ORGANIZATION TO UNLEASH THE FULL POTENTIAL OF END-TO-END OPERATIONS1

2013: reinforcement of European Operations

to leverage synergies across the full Value Chain

Our Value Chain goes from the farm to the fridge

Page 8: EUROPEAN OPERATIONS RESET MODEL - danone …danone-danonecom-prod.s3.amazonaws.com/user_upload/Investisse… · Construction of Danone Dairy Production System Work with each plant

Salas

Castello

ParetsTres Cantos

Aldaia

VillecomtalSt Just

Casale

MolayDPB

Bailleul

Rotselaar

Hagenow

Ochsenfurt

Rosenheim

Budapest

Benesov

Warsaw

Bierun

Bucharest

Sofia

Tenerife

Lunnarp

Sevilla

2013Sale of Castello, Benesov, Sofia

Closure of Sevilla

2014Sale of Tenerife

Closure project of Casale, Budapest, Hagenow

A DEEP DAIRY FOOTPRINT CONSOLIDATION TO BETTER CREATE VALUE AND STRENGTHEN COMPETITIVENESS

European network – 16 plants by mid 2015

Network optimization from 24 plants

in 2013 to 16 plants in 2015

2

Better assets utilization: +8pts YE15

and +15pts by YE18

Clear technology and European

sourcing role for each dairy plant

Page 9: EUROPEAN OPERATIONS RESET MODEL - danone …danone-danonecom-prod.s3.amazonaws.com/user_upload/Investisse… · Construction of Danone Dairy Production System Work with each plant

Selection of operational KPIs

Approach de-averaged by process technologies

Identification of performance gaps / assessment of plant maturities

Detailed operational standards for each performance topic

Documented support for each plant to progress in its practices

Construction of Danone Dairy Production System

Work with each plant on a single reference document gathering all productivity projects in next 2-3 years

Roadmap fully owned by the plants

Ideal Factory proposal 12mar14 - 18 mars v10.pptx 76Draft—for discussion only

Copyri

ght

© 2

014 b

y T

he B

osto

n C

onsultin

g G

roup,

Inc.

All r

ights

reserv

ed.

2.0

1.5

1.0

0.5

0.0

M€ de Capex

total Capex vague 1

1.6

Capex à déterminer

?

Payback

> 4 ans

0.1

Payback

compris

entre 2

et 4 ans

1.1

Payback

<= 2 ans

0.4

Répartition des Capex des initiatives selon leur durée de payback (vague 1)

Première estimation des besoinsen Capex par usine

1.2 M€ de gains associés à des initiatives nécessitant des capex5 initiatives capex sur 9 ont des payback inférieurs à 2 ans

Gains associés(M€)

Nombre d' initiatives

0.5 0.5 0.0 0.2 1.2

5 2 1 1 9

Source: Entretiens avec les membres du CODU, baseline E1 2013, analyse BCG

# InitiativeGains

(k€)

Cape

x (k€)

Estimati

on du

payback

(années)

VLC-24 Chargement par les chauffeurs 375 200 0.5

VLC-31 Arionic pré-traitement Gaz 50 40 0.8

VLC-29 Eclairage à leds des ateliers H24 30 40 1.3

VLC-36 Obus masses blanches 40 65 1.6

VLC-30Isolation des échangeurs boucles NEP

30 50 1.7

VLC-07Initiative Eole (automatisation des plieuses)

360 750 2.1

VLC-10 Augmentation de la cadence 100 300 3

VLC-28 Instrumentation consos 25 130 5.2

VLC-32 Divers PNI avec CAPEX 170 TBD TBD

Total 1180 1575

CONFIDENTIEL

29Les informations et propositions contenues dans ce document sont des hypothèses de travail et ne constituent en aucun cas des décisions de changement d’organisation.Aucune décision éventuelle ne serait prise sans consultation des représentants du personnel conformément à la loi. Leveraging DPFF Project Villers Cotterets' experience 17 fév v3.pptx

1. Réduction des fréquences de fabrication – lien de l'ordo avec les interfaces lait vu en parallèle 2. Principalement DPB et VLC (enjeux plus importants sur les fruits) 3. Optimisation des CFU avec le chargement par les chauffeurs et changement des organisationnels 4. 21.5 ETP dans les DL locales sur site usine 5. Hors fermeture WE des sites. Impact headcounts à prévoir 6. Impact intérim : indus réparti de 2014 à 2016, supply de 2015 à 2017 Note : Chiffrages arrondis Source : Interview, Analyses BCG

2014 2016 20172015

Vision d'ensemble du phasing possible des initiatives et impact ETP

Initiatives locales

Initiatives transverses1

/ avec pilotage central3

Vague 1 – suivi du phasing du plan détaillé par usineVague 1 – suivi du phasing du plan détaillé par usineVague 1 – suivi du phasing du plan détaillé par usineVague 1 – suivi du phasing du plan détaillé par usineVague 1 – suivi du phasing du plan détaillé par usineVague 1 – implémentation du plan détaillé par usine : - 172 ETP (- 57 par an)

Vague 2Vague 2Vague 2Vague 2Vague 2Vague 2 : - 43 ETP

Fréquences de fab : - 4 ETP (-1, -3)

Optimisation des CFU : - 36 ETP (- 15, -18, -4)

Volumes européens : + 17 ETP

Vague 2 CFU : - 3 ETP

Optimisation des organisationnels5 : - 16 ETP (- 8, - 8)

Supply

Lait

Impact ETP6

(Total : 406)80 ETP

(21 intérim)121 ETP

(38 intérim)125 ETP

(38 intérim)80 ETP

(18 intérim)

Optimisation de la collecte : - 11 ETP (- 4, -7)

Sites laitiers : - 13 ETP

OVH DL : - 25 ETP4 (-7.5, -7.5, -10)

A intégrer dès 2014 Vague 2 ou en local

Réduction fréquence de livraison : - 50 ETP (- 4, -13, -21,-12)

Mécanisation et autres leviers supply : - 50 ETP (- 11, -28, -11)

CONTINUOUS IMPROVEMENT REMAINS OUR CULTURE: A GLOBAL IDEAL FACTORY PROGRAM RECENTLY LAUNCHED…2

BENCHMARKS STANDARDS ROADMAPS

Page 10: EUROPEAN OPERATIONS RESET MODEL - danone …danone-danonecom-prod.s3.amazonaws.com/user_upload/Investisse… · Construction of Danone Dairy Production System Work with each plant

Unique reach

@ Best Total Cost

Co-Logistic / Co-Distribution

Total Cost To Serve

Go To Market

Superior execution @ Point Of Sale

For all customers

Best freshness

Differentiating from competitors in each

market where we operate

In a sustainable manner

(will last over time)

Generating value

Generating customer / shopper preference

SUPPLY CHAIN: A KEY ASSET TO DELIVER FRESHNESS AND COMPETITIVENESS TO DIFFERENTIATE AT POINT OF SALE3

Page 12: EUROPEAN OPERATIONS RESET MODEL - danone …danone-danonecom-prod.s3.amazonaws.com/user_upload/Investisse… · Construction of Danone Dairy Production System Work with each plant

THE EUROPEAN VALUE CREATION MODEL AND INITIATIVES ARE AS WELL ROLLED-OUT GLOBALLY

01 Integrated Operations

organization

02 Manufacturing

Competitiveness 03 Supply Chain

Co-partnerships