Production SOPs — Field Quick Guide

At a Glance

📑 SOP Index – Production

🔧 Step 1: The Sales Director provides the Annual Sales Forecast for the upcoming year by the end of the current year.🔧 Step 2: The Production Manager prepares the Annual Raw Material Plan based on the sales forecast and shares it with the Procurement Manager for budget estimation and sourcing arrangements.🔧 Step 3: The Production Manager prepares the Annual Production Plan in alignment with the Annual Sales Forecast. Production is scheduled one month in advance of the corresponding monthly sales forecast (e.g., February sales are produced in January).🔧 Step 4: As part of the Annual Production Plan, the Production Manager also prepares the Annual Manpower Plan based on man-hours.
💻 System: Partially
✅ Implemented: ✔️

🔧 Step 1: The Annual Production Plan is broken down into monthly plans, which are referred to as the Monthly Production Plan.
💻 System: Partially
✅ Implemented: ✔️

🔧 Step 1: Based on the Monthly Production Plan, the Weekly Production Schedule is prepared by Production Supervisor before the beginning of each week and shared with key stakeholders, including the Quality Control, Stores (FG & RM) Department, Maintenance Department and Production Manager.
💻 System: Partially
✅ Implemented: ✔️

🔧 Step 1: Based on the Weekly Production Schedule and in alignment with the daily stock report of finished goods received from the Warehouse In-Charge, daily production is planned. Planning is done at least two days in advance.🔧 Step 2: Based on the production plan, a Material Request is placed in the RBS system, anticipating the production needs for at least two days ahead.🔧 Step 3: The Maintenance and QC teams are contacted by Production Supervisor verbally to allocate a production line.🔧 Step 4: The Maintenance In-Charge ensures that the production line is ready as per the production plan.🔧 Step 5: The Quality Control In-Charge ensures that CIP (Clean-in-Place) procedures are implemented on-site.🔧 Step 6: The Production Supervisor prepares the Weekly Duty Schedule, and based on it, daily manpower resources are allocated.🔧 Step 7: The Material Start-Up Checklist is followed before each production batch.🔧 Step 8: Start and stop times, along with breakdown details, are recorded in the Machine Breakdown Report for each shift.🔧 Step 9: At the end of each day's production process, the Shift-In-Charge prepares a Production Report containing the details of each batch. The Breakdown Report, along with all Shift-In-Charge reports, is summarized, and the Production Manager signs the Breakdown Summary Report.
💻 System: Partially
✅ Implemented: ✔️

🔧 Step 1: The Daily Production Line Report, prepared on a batch-wise basis, will include details such as BOM utilized, production count, wastage, breakdowns, energy and water consumption, etc.
💻 System: Partially
✅ Implemented: ✔️

🔧 Step 1: Finished products, arranged pallet-wise, will be moved to the designated area.🔧 Step 2: The Production Supervisor will count the products and label them.🔧 Step 3: The product count details will be recorded in the Daily Production Handover Report, and the Warehouse In-Charge will sign and acknowledge receipt.
💻 System: NO
✅ Implemented: ✔️

🔧 Step 1: The combination of primary material ingredients must follow the PCI Beverages instructions. However, packing materials can be selected flexibly from the approved list of products/vendors.
💻 System: Partially
✅ Implemented: ✔️

🔧 Step 1: Following a market study, a decision is made to introduce a new product, flavor, or packaging format (e.g., new can or bottle).
In case of a new product, the Production Team will be given six months to organize the required raw materials.
In case of a bottle type change, the Production Team will be given one month to organize the required raw materials.