TRADE COMPANY «RUS-STEKLO» - PDF

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Limited liability company TRADE COMPANY «RUS-STEKLO» LLC «TRADE COMPANY «RUS-STEKLO» Trade Company Rus-Steklo realizes glass tare manufactured by 4 production plants: LLC Sergiev Posad glass

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Limited liability company TRADE COMPANY «RUS-STEKLO» LLC «TRADE COMPANY «RUS-STEKLO» Trade Company Rus-Steklo realizes glass tare manufactured by 4 production plants: LLC Sergiev Posad glass factory, LLC Omsk glass factory, LLC Kingisepp glass factory LLC Velikodvorsky glass factory. LLC Rus-Steklo and manufacturers form their relationship on a contract basis. The capacities of manufacturers completely satisfy the demands of LLC Rus-Steklo. Exclusive jar and bottles are objects of intellectual property and are manufactured only under orders of LLC Rus-Steklo LLC TRADE COMPANY «RUS-STEKLO» Kingissepp glass factory Sergiev Posad glass factory Omsk glass factory Velikodvorsky glass factory Company s share at the Russian market is 22% GLASS FACTORIES MISSION: Provide glassware to the domestic and foreign customers surpassing their expectations Sergiev Posad glass factory design capacity 800 mln pcs. of glassware per year Omsk glass factory design capacity 390 mln. pcs. of glassware per year Kingissepp glass factory design capacity 680 mln. pcs. of glassware per year Velikodvorsky glass factory design capacity 200 mln. pcs. of glassware per year PRODUCTION RESULTS GROSS PRODUCTION OUTPUT, (pcs) SPSZ VSZ OSZ KSZ TOTAL: PRODUCTION CHARACTERISTICS Designer of the dosing and mixing line Designer of the furnace equipment SPSZ KSZ VSZ OSZ Glass Establishment (Italy) - Glass Technologies (Italy) Teco Glass (Great Britain) ZAO Stekloavtomatika (Russia) Glass Technologies (Italy) AMC GLASS (Italy) HORN Glass Industries AG (Germany) Estimated capacity, ton/day Melting area, m Refractory materials KPOK CRRC (China) SEPR (France, India) Start-up year Linies quantity Sections quantity 8 / 6 8 / 10 / 12 6 / 8 8 / 12 Glass-forming machine BDF 5½, Bottero 6¼ Bottero 6¼ Bottero 5½ BDF 5½ Annealing lehr Antonini (Italy) CAR-MET (Italy) Control measurement devices StromI (Russia)) Antonini (Italy) Bush&Spreen (Germany), AGR (USA), IRIS (France), MCAL (France), MULTI (France), M1 (SGCC), FLEXT (Emchart Glass) Conveyor lines, palletizer All Glass (Italy) Gemco (Holland), CAR-MET (Italy) Steklopack (Russia) All Glass (Italy) Termal shrinking machine MSK (Germany) Emmeti Sipac (USA) Steklopack (Russia) MSK (Germany) INTEGRATED MANAGEMENT SYSTEM Based on the requirements of ISO 9001, ISO 22000, BRC/IoP standards THE POLICY OF END PRODUCTS SAFETY AND QUALITY SAFETY AND QUALITY AIMS FOR THE END PRODUCTS IN nd rule of the Quality Management System: Management leadership INTEGRATED MANAGEMENT SYSTEM THE LEVEL OF ACHIEVEMENT OF THE QUALITY OBJECTIVES, % SPSZ ,1 88,6 96,9 94,2 93,8 93,4 CUSTOMER SATISFACTION, index 93,46 94, ,6 92,2 92,67 92, INTEGRATED MANAGEMENT SYSTEM QUALITY RELATED GOAL ACHIEVEMENT LEVEL for the period % 90% 80% 89% 89% 96% 91% 96% 80% 84% 100% 86% 97% EXCELLENT GOOD 70% SATISFACTORY 60% 50% 59% 58% СПСЗ КСЗ ВСЗ ОСЗ PRODUCTS SAFETY December 2013 Safety and quality management system certification for correspondence to the requirements of the Global Standard for Packaging and packaging Materials BRC/IoP (v.4) BRC British Retail Consortium IoP Institute of Packaging Certificate of conformity of Grade achieved А Site BRC: company code INTEGRATED MANAGEMENT SYSTEM Integrated safety and quality management system (ISM), meeting the international standard BRC/IoP requirements, functions at all 4 plants from Conformance of ISM at the plants to the BRC/IoP requirements is evidenced by periodic third party audits (external audits). Positive results of external audits were obtained by the following companies: год: SAIGLOBAL SPSZ (certificate BRC, category А) год : NestleKuban KSZ ROUST SPSZ, KSZ, OSZ, VSZ ОmskVinProm VSZ Aqualife SPSZ год Jacobs-Rus KSZ ROUST ОSZ Aqualife, ОmskVinProm, NestleKuban СПСЗ N o t e: BRC/IoP International standard for packing and packing materials. The standard was first accepted in 2001, published by British Retail Consortium (BRC) for consumer protection PRODUCTS The glass factory produce more than 300 types of flint glassware for: baby food products, distilled beverages, cognacs and liqueurs, vines and drinks, beer, fizzy drinks, mineral water, low-alcohol beverages and soft drinks, preserved fruit and vegetable products, coffee and coffee products, milk and milk products, fish products. Glassware made at the glass factories is notable for the high European quality, it is ecologically clean, it has a high water and chemical resistance, it is durable and light, its geometry is ideal, And it differs for the exclusive design PRODUCTION DEVELOPMENT 2014 The COLOURED container s glass is made for the food and perfumery-cosmetic production according to GOST Р Glass COLOURING is made by adding glass fritt to the feeder channel (on one machine-line) Mass concentration of glass frit (Co, Mn) is from 0,05 to 3 % 6 th rule of the Quality Management System: Constant improvement OUR CUSTOMERS Baby food: «Progress», «Sady Pridonya» Coffee: «Mondelez», «Nestle», «Megapolis»(Sara Lee), «Center Snub» Vodka: «ROUST» (CEDC), CJSC Yerevan Brendy Company (Pernod Ricard), «Rospischesnab» «OmskVinProm», «Russkiy Sever» Juices, Preserved food: «Multon» (Coca-Cola), «Selizharovsky canning factory» «Baltimor» CONFORMITY OF GOODS UNITARY STANDARD for the output products DECLARATION of the products conformity to the requirements of the Technical regulations ТС «Packaging safety» PRODUCTS SAMPLES TESTS in the accredited laboratories (of the Customs Union) SAFETY MANAGEMENT HAZARD BIOLOGICAL CHEMICAL PHYSICAL RISKS' DETECTION AND ANALYSIS MAIN WORK DIRECTIONS : implementation of HACCP documenting and increasing of Quality system effectiveness production environment, personnel, products, processes and ecological aspects control production standards, products and personnel control HACCP PLAN CRITICAL CONTROL POINT MONITORING Current control and constant quality, hygiene and product safety improvement PRODUCTION AREA Batch house Furnace Hot end Cold end Warehouse 1. Batch preparation 2. Batch and cullet supply into the furnace 3. Glass melting 4. Glass mass preparation for forming 5. Glassware molding 6. Hot end coating application 7. Annealing 8. Cold end protective coating application 9. Glassware quality inspection 10. Packaging 11. Glassware delivery to the customer 4 th rule of the QMS: Process approach 5th rule of the Quality Management System: System approach to management BATCH HOUSE 8 th rule of the Quality Management System: Mutually beneficial cooperation with the suppliers GLASS-MELTING FURNACE GLASS-MELTING FURNACE EQUIPMENT CENTRAL FACTORY LABORATORY X-ray fluorescence wave-dispersive spectrometer S4 PIONEER Raw materials incoming inspection Chemical composition analysis of glass, raw and auxiliary materials Products water and acid resistance tests Chemical composition analysis Elements analysis Tested concentrations range is from ppm to % GLASS-FORMING MACHINES DOUBLE GOB glassforming machines BDF, Bottero 6 sections 8 sections 10 sections 12 sections QUALITY CONTROL AT THE HOT END Controlled parameter Method Cycle 1.Visual defects Visual inspection 2. Geometrical dimensions 3. Weight, g Gauge CORK Gauge - CLAMP Vernier height gauge Automatic scales EVERY HOUR 1 sample from each form Glass machine operator Products thermogram analysis after forming process ANNEALING QUALITY CONTROL Residual strength level control Измерительная головка Головка окуляра Окуляр Анализатор Шкала лимба Диск переключения пластин Лимб матового стекла с оцифровкой от 0 º до 360 º ANTONINI ANNEALING LEHR Тумблер включения/выключения прибора Ручка переключения пластин λ и λ/4, находящихся внутри прибора Матовое стекло, на которое ставится образец Индекс лимба для снятия отсчета Ручка для вращения матового стекла с образцом Педаль для включения лампы Polariscope-polarimeter ПКС-250М PROTECTIVE FORTIFYING COATINGS AGR equipment Hot-end coating control Cold-end coating COLD END CONSTANT VISUAL INSPECTION CCP-1 The samples of glassware faults detected at the viewing screen inspection: Register «Мonitoring CCP-1» every 30 min TECHNICAL QUALITY INSPECTION THE LIST OF CONTROLLED PARAMETERS LINE INSPECTION PLAN Controlled parameter Method Cycle 1.Visual defects Visual inspection EVERY 2 hours 2. Geometrical dimensions Gauge - CORK Gauge - CLAMP Height gauge, Thickness gauge, probes, line gauge EVERY 2 hours ONCE PER SHIFT WORKING AREA OF QUALITY INSPECTION CONTROLLER FAULTS SAMPLES FOR THE INSPECTION EQUIPMENT ADJUSTMENT Inspection tools: PHYSICAL LABORATORY OF QUALITY INSPECTION PHYSICAL PARAMETERS CHECK TESTED PARAMETER TEST FACILITIES FREQUENCY 1 MASS Automatic weigher 2 CAPACITY Scales, funnel, glass plate sliding caliper, thermometer jars every 6 hours bottles every 3 hours 3 times per shift or every 4hours 3 IMPACT RESISTANCE Pendulum impact tester IT (company AGR) once per shift 4 COMPRESSION LOAD 5 INTERNAL HYDROSTATIC PRESSURE 6 HOT SPRAYING THICKNESS Tester facility VLT, company AGR, together with RPT-2 Tester facility RPT-2 (company AGR) Tester facility FCMS, company AGR Tester facility HECM, company AGR once per shift for bottles ШК, РК, ГК groups every two hours for other articles once per shift every 6 hours 7 THERMAL RESISTANCE Thermal bath (company AGR) every 12 hours 8 ANNEALING Polariscope-polarimeter PKS-250M every 2 hours 9 COLD SPRAYING Tilting table LUBRICITY (company AGR) every 2 hours DATA STATISTIC ANALYSIS PARETO DIAGRAM, GRAPHS GLASSWARE FAULTS CLASSIFIER 7 6 4,8 Доля партий,принятых с замечаниями Доля партий, на которые получены претензии 5 4,2 3,8 4 2, ,2 1,5 1,8 1,5 0 октябрь ноябрь декабрь Итого 7 TH rule of QMS: Take decisions based on facts AUTOMATED QUALITY INSPECTION MCAL INSPECTION (FRANCE) Main test parameters: - critical faults: glass birdcage, glass stick - visual body faults: foreign inclusions, bubbles, tears - geometrical dimensions: diameter, height, perpendicularity - quality of annealing MULTI INSPECTION (GERMANY) AUTOMATED QUALITY INSPECTION Main test parameters: - critical faults: glass birdcage, glass stick visual bottom faults: tears, foreign inclusions, bubbles - visual finish faults (from 40 mm); - mould code reader (alfa-code, dot-code, LMNC) AUTOMATED QUALITY INSPECTION SGCC inspection M1 Main test parameters: - finish inner diameter - wall thickness - top of the finish planeness - checks AUTOMATED QUALITY INSPECTION EMHART GLASS inspection Main test parameters: - visual body faults: foreign inclusions, bubbles, tears - geometrical dimensions: diameter, height, perpendicularity - quality of annealing PRODUCTS SAFETY POLLUTION AND INGESTION CONTROL SPECIAL CONTROL: Baby food and coffee OBLIGATORY RUN-UP (GMP, PRP) EXTERNAL VIEW REQUIREMENTS : At the territory of production : IT IS NECESSARY to put on workingwear: - work suit or gown; - headwear Hair should be tucked under the headwear SANITATION LOG: PROHIBITED: to wear on hands jewelry with stones and watch walk through the workshop is allowed only by the balcony! to eat; to keep food and drinks, use chewing gum, drop litter to cross the routes of transportation machine Shuttle ALLOWED: Smoking only in the specially allotted places! To take glass tare into hands only in gloves! It is necessary keep out of the way of car-lift trucks! PALLETIZING Register «Мonitoring CCP-2» - every 3 hours CCP THERMAL SHRINKING MACHINE AUXILIARY MATERIALS FINISHED PRODUCT STORAGE Condition 2: covered unheated warehouse Condition 5: shelter Condition 9: open platform DISPATCH CCP-4 DISPATCH REQUIREMENTS QUALITY PASSPORT CONSUMER'S LABEL CUSTOMER S SATISFACTION MEASURED VALUES: Returns level Proportion of the products accepted with comments Defects level in the defects groups ADMINISTRATION: Problems analysis Complaints reasons analysis Corrective actions HOW OFTEN THE DATA IS TO BE PROVIDED - ONCE A MONTH PRODUCTS RETURN LEVEL IN %, monthly average 1,5 1,0 1, ,5 0,0 0,27 0,31 0,19 0,06 0 0,04 0,03 СПСЗ КСЗ ВСЗ ОСЗ Glass factories supplying the products of LLC «TC «RUS-STEKLO» RETURNS LEVEL DIAGRAM Information from: LLC SERGIEV-POSAD GLASS FACTORY during PRODUCT FRACTION ACCEPTED WITH COMPLAINTS Information from: LLC «Sergiev-Posad Glass factory» received by THE BATCHES PARTLY RECEIVED WITH CLAIMS 4 3 3, ,74 1,60 1,01 0,84 0,74 0,44 0,65 СПСЗ КСЗ ВСЗ ОСЗ Dynamics of the figure during FAULTS LEVEL IN THE FAULTS' GROUPS Information from: LLC SERGIEV-POSAD GLASS FACTORY during 2015 Faults level (ppm) A - critical Б - dangerous В - considerable COMPLAINTS REASONS ANALYSIS CLAIM CONTROL CARD 1 st rule of QMS: Customer orientation 3rd rule of QMS: Personnel involvement 6th rule of QMS: Constant improvement Инциденты ( мембрана, прилип стекла, посторонние тела в изделиях) Дефекты внешнего вида ( сколы) Скрытые дефекты (бой на линии) Геометрические дефекты (вн. диам. венчика, вогнутость кальеретки, тонкая стенка, отклонение от перпендикулярности) Бой при транспорт. Качество упаковки (мокрые поддоны, нарушение геометрии паллета) - RETURNS ANALYSIS Information from: LLC SERGIEV-POSAD GLASS FACTORY during % SHORT-TERM OBJECTIVES: INVESTMENTS AND NEW PROJECTS SPSZ: As part of commissioning of glass furnace No. 1 in April 2014 after cold repair the following was done: scheduled repair of annealing furnace repair of product transportation lines and palletizers installation of new inspection equipment capital repair of glass-forming machines with partial replacement of mechanisms by more advanced ones installation of a new glass-forming machine on the machine line 1-5, allowing to manufacture articles in the wider range of geometrical dimensions in comparison to other glass-forming machines. Also, equipment for glass coloration in the feeder was installed in the line, which allows to obtain actually any colour of glass. As part of of cold repair of glass furnace No. 3 it is planned to: reconstruction of machine lines , product transportation lines and palletizers capital repair of glass-forming machines with partial replacement of mechanisms by more advanced ones installation of a new glass-forming machine on the machine line 3-1, allowing to manufacture bottles using the NNPB method. Provisional dates of commissioning of furnace No. 3 October-November 2015 VSZ: As part of commissioning of glass furnace after cold repair the following was done: scheduled repair of annealing furnace repair of product transportation line and palletizers installation of new inspection equipment capital repair of glass-forming machines with full replacement of mechanisms by more advanced ones Full reconstruction of machine lines ОSZ: Production operations. КSZ: INVESTMENTS AND NEW PROJECTS LONG-TERM OBJECTIVES: SPSZ: Reconstruction (cold repair) of glass furnaces Nos. 2, 3. VSZ: Switch to production of more sophisticated exclusive kinds of articles on the glass extra-flint. OSZ: Construction of the 2-nd production stage of OSZ: glass furnace No. 2 (5 machine lines). KSZ: Cold repair of the 2-nd production stage Thank you for your attention!
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