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Case Study; Innovation at Firm Level
INNOVATION THROUGH
AUTOMATION
1
Salem Nasser Al-Bortmany
A Case Study
Areej Vegetable Oils
& Derivatives (AVOD)
INDUSTRIAL INNOVATION FORUM
2
Outline of the presentation
AVOD’s Business Model & Challenges
Managing changes through Innovation
AVOD’s Innovation Value Chain
History of Innovation & Automation
Bottle and handle fixing
Robotic palletization
Automation in warehouse and logistics
Link on AVOD’s Innovation through automation
AREEJ VEGETABLE OILS & DERIVATIVES
(AVOD)
BUSINESS MODEL
About the Factory:-
Established in 1982
Current Plant Capacity : 240kMT
Export : 80%
Total Employees : 736
Omani : above 53%
Customer Mix : Institutional, bakeries, wholesales, retailers, modern
trades.
Export Customer Mix : AVOD’s brands, MNC’s brands, potential
customers brands.
3
GLANCE ABOUT AVOD
Products Range :-
• Vegetable oils, vegetable ghee, margarine, butter, specialty
fats, shortenings, mayonnaise, dressings.
4
5
Uncontrollable External Factors :-
13 Factories in GCC for edible oils and fats.
Installed capacity more than 2 million MT per year.
GCC consumption estimated at 0.7 million MT per year.
35% utilization, GCC is a net exporter of edible oils and fats.
Stiff competition, more than 45 brands in the market.
Increasing bargaining power of retail & distribution channels
Change of legislation, regulations and laws; products, labeling
Non-tariff barriers of entry & logistics issues within the GCC.
Continuous increase in operating costs, utility costs, logistics,
BUSINESS CHALLENGES
6
Changes through Innovation:-
Process Innovation (RBDF)
Manufacturing Innovation (Automation)
System Innovation (ERP SAP, WMS)
Products Innovation (AVODs, MNCs)
Utilization of modern technology
Upgrading HR skills & operating systems
MANAGING CONTROLLABLE FACTORS
INNOVATION
THROUGH AVOD’s VALUE CHAIN
7
Critical Needs & Requirements Identify frying habits; taste, lightness.
Innovation Cycle
Create Product Value Physical / Clarity /Colour/Bottle & caps
Actively Engaged Customers
Partnerships / loyal / Quality
Strategy
Resources
Competences
Operation Cycle
Service Cycle
8
DEFINITION OF INNOVATION
“The implementation of creative ideas in order to generate value,
through increased revenues, reduced costs or both”
“Executing an idea which addresses a specific challenge and
achieves value for both the company and customer”
• A Add
• V Value
• O On
• D Day-to-day activities
VALUE ON BOTTLE BLOWING
9
Improvement in Process Technologies
Manual Handle Fixing
Improvement in Process Technologies
Handle Fixing
BENEFITS FROM HANDLE FIXING AUTOMATION
• Utilize capacity by aligning bottle making and filling lines.
• Increase productivity, double the output.
• Accuracy in handle fixing.
• Eliminate rejection/wastages.
• Operate in hygienic and safety environment
• Upgrade skills of same team
to handle automated systems.
Improvement in Process Technologies
Robotic Palletization
Improvement in Process Technologies
Robotic Palletization
Improvement in Process Technologies
Robotic Palletization
Advantages on Robotic Palletization
• Increase in productivity, double the output.
• Eliminate incidents and accidents of stacking manually.
• Reduce higher turnover of employees
• Increase overall safety of workers
• Upgraded the Skill of workforces
• Increase food safety & hygienic work environment
Improvement in Loading & Material Handling
Improvement in Logistics and WMS
Semi Automated Warehousing
20
Automated Warehouse – Automha
BENEFITS FROM WAREHOUSING AUTOMATION
• Fully automated warehouse
• Better Space Utilization.
• Pallet position more than 15k
• Managing FIFO effectively.
• Real time Traceability
• Accuracy in Warehousing, physical stock vs system
• Eliminate multiple handling, maintain quality.
• Upgraded skills to handle automated systems
Skill Up-gradation
System Innovation
Update
Master Data
in SAP
Master Data is
uploaded in
WMS
AUTOMHA is
updated with
Master Data
Integrated System Design
Boomi SAP WMS
AUTOMHA
Location
• WMS provide visibility on stock in AUTOMHA by Item & Batch
• AUTOMHA control the stock movement inside the storage area
• Ability to maintain several locations under AUTOMHA
• SAP controls order-to-despatch.
System Integration
Inbound (Production – WMS)
Creation Production Order
in SAP
ASN is created in WMS
Inbound Planner prepares ASN and
prints IDs
Receiving of produced pallets in
Whrs using RF
Putaway to be done in AUTOMHA
AUTOMHA will confirm Putaway in
WMS
ASN Confirmation ( WMS – SAP)
System Integration
Outbound (SAP – WMS – SO)
Creation Sales Order in SAP
SO is created in WMS Allocation of Orders
in WMS (From AUTOMHA)
WMS to release picking tasks to
AUTOMHA
Stock Moved to STAGE.
AUTOMHA to confirm picking tasks in WMS
Picking to start using pick list printed from
WMS
SO Confirmation
( WMS – SAP)
Overall Automation Benefits
• Upgrade staff to skilled, specialist, supervisors
• ROI (Robots and automation) = 3 years
• Improve overall productivity = more than 35%
• Reduce or eliminate routine manual work
• Improve product quality
• Eliminate waste
• Increase loyal customers
• Reduce order-to-delivery lead time
• Improve profitability
• Increase market share
• Expanding and increase in capacity
28
Overall Automation Benefits
Local and Export Sales Growth
29
0
20000
40000
60000
80000
100000
120000
140000
2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016
CAGR = 17.5%
Local Export
MT
INNOVATION THROUGH AUTOMATION
30
“Innovation remains as the ability to convert ideas into invoices” “Business can survive only if it’s globally competitive”
INNOVATION THROUGH AUTOMATION
31
THANK YOU