EXCELLENCE AWARD FOR TPM
ACHIEVEMENTTANGAMANGA PLANT
Sigma Alimentos

Confidential Information

EXCELLENCE AWARD FOR TPM ACHIEVEMENT

1. COMPANY PROFILE
Alfa group is a company that administrate and impulse a large portfolio of businessleaders on food (Sigma) and petrochemicals (Alpek) with international presences,providing products and services to improve people’s quality life.
The group counts with presence in 25 countries at the continents of America, Europe,and Asia.

Sigma Alimentos is one of the largest, refrigerated food companies in the world,
operating in 17 countries, whit a large portfolio of categories and added value brands,
which are highly recognized and considered leaders in their categories and marketsegments, to offering the favorites foods of the communities.
Sigma Alimentos has the largest refrigerated distribution network in Latin America,
which is one of its strengths.

51%
Alfa Revenues

59%
Alfa EBITDASIGMA ALIMENTOS TANGAMANGA PLANT

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EXCELLENCE AWARD FOR TPM ACHIEVEMENTSIGMA ALIMENTOS TANGAMANGA PLANT

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EXCELLENCE AWARD FOR TPM ACHIEVEMENTThe Tangamanga plant was founded in 1973 by master ham makers coming from a
traditional Spanish family who mastered culinary arts of Spanish, Italian, German,and English houses.
In 1999 Tangamanga became part of Sigma Alimentos, being the only plant
specialized in the production of delicatessen and gourmet products. Tangamanga islocated in the state of San Luis Potosí, this ubication brings with it a logisticaladvantage because the plant is in the middle of a triangle formed by the main citiesof the country: Guadalajara, Monterrey and Mexico City.

The Tangamanga plant has a wide selection of matured and cooked products among
which the mains are the pepperonis, salamis, fine hams, and sausages. Currently
there are 82 SKUS in total.

We have a staff of 154 employees divided into 3 shifts working 6 days a week.
SIGMA ALIMENTOS TANGAMANGA PLANT

3EXCELLENCE AWARD FOR TPM ACHIEVEMENTThe Tangamanga plant has a 43% share in the Delicatessen market, being theleading brand in the country.

At Tangamanga we strive for innovation throughout the plant, in processes, products
and machines, while maintaining our traditional signature style.

2. MILESTONE ON THE JOURNEY OF MANUFACTURING EXCELLENCE
Seeking to have with a standardized management system for all Sigma Alimentos
factories, in 2015 the Tangamanga plant starts TPM activities under the mentoringof JES consultants. Seeking highly efficient people, processes, and machines withthe least possible losses, we started with 4 pilot teams of Autonomous Maintenancein the most critical production lines of the plant with support from pillar leaders
forming part of the pilot teams.
In this same year, 2015, the TPM committee was formed with the participation of the8 pillar leaders, who were trained in the activities and methodologies of each pillar.
The indicators to be managed were selected according to the plant’s strategy andthe master plan was created with all the activities of each pillar scheduled. Thismaster plan is a guide to follow the path to excellence.
Two years later in 2017 our TPM “Kick Off” takes place, in this event the entire plantparticipates with great enthusiasm to learn about the work done by the pilot teamsof Autonomous Maintenance and officially start with TPM activities in all areas of theplant through the 8 pillars.
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EXCELLENCE AWARD FOR TPM ACHIEVEMENT

After the “Kick Off” event, first generation Autonomous Maintenance teams werecreated adding 3 production lines, three more lines were incorporated in a second
generation in 2018 and in 2019 the third generation starts with another 2 lines.
Finally, in 2021 the services were incorporated as Autonomous Maintenance teams
to total 17 teams and have 100 % of the plant’s machines with Autonomous
Maintenance pillar activities. In addition, we can say that 100 % of plant personnel
participate in TPM activities.
During the COVID-19 pandemic since the beginning of 2020, it was necessary a retraining in TPM issues to the personnel who had to support in different extra activitiesof other pillars due to the lockdown of some collaborators as well as thosecollaborators in lockdowns took remote training and performed activities from home.
Thanks to all the standardized TPM activities developed by the 8 pillars, theTangamanga plant was able to avoid the negative effects caused by the COVID-19
pandemic without affecting the business continuity.
In 2022 all the work done by each pillar since the beginning of the TPM
implementation was presented in an internal event with great success, which
motivated the plant to seek the Excellence Award for TPM Achievement, maintainand improve that teamwork to be an excellent plant with excellent results.

SIGMA ALIMENTOS TANGAMANGA PLANT

5EXCELLENCE AWARD FOR TPM ACHIEVEMENT

3. BENEFITS ACHIEVED
The implementation of TPM in the Tangamanga plant, has made many benefits
among the most important are a great sense of belonging of the operators to theirworkplace, this can be seen in the commitment to perform all activities related to
TPM for create and sustain an ideal working environment to develop their daily
activities with safety, quality, and efficiency.
Another benefit is to have a system to identify any anomaly in a timely manner tohelp us prevent losses, and a common language was also created between thedifferent pillars to help create better communication and greater understanding.
Thanks to TPM we have collaborators with more skills and better level, proof of thisis a machine designed and manufactured in Tangamanga to wash plastic crates byusing obsolete equipment. With this machine we were able to save USD$102,500.00 by avoiding the purchase of a new one and also reassign 3 operators
to other activities.

4. KEY OF OUR MANUFACTURING EXCELLENCE
The main key of our manufacturing excellence is the plant’s committed people. Thisis an achievement obtained through improvements in processes and machinery.
These improvements were developed in most cases, with multidisciplinary teams
and the main actors were the frontline employees, who gave their point of view andin this way realized that they are listened to generating a change of attitude in thesearch for continuous improvement.
The continuous training to learn new TPM methodologies for loss analysis, resolution
and prevention is another major key in manufacturing excellence, because the skillsof all personnel increase and a strong TPM system is generated. The implementationof these methodologies must become a habit in order to cope with any losses thatthe plant may arise.
Finally, tangible, and intangible results are the motivation for staff to embark on apath to excellence. This path to excellence and all the activities required to achieve
it are described each year in the plant’s strategy and is transmitted to all those whoare part of the structured organization, starting with the manager and the pillar
SIGMA ALIMENTOS TANGAMANGA PLANT

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leaders who define the specific objectives of each pillar to transform the individual
activities of each collaborator into common objectives.

5. ACHIEVEMENT RECORDTPM Award Assessment Achievement Sheets
Company & plant
name

SIGMA ALIMENTOS CARNES SELECTAS TANGAMANGA S.A DE C.V

TPM Kick Actual statusTarget 2023
Off 2017
2023

CategoryIndex

UnitS

Number of work-related accidents
requiring days off work

Cases/year

1510S

Number of work-related accidents norequiring days off work

Cases/year

4050P

Productivity

Ton/operator

1.89

2.22

2POEE%

54%

75%

77%

P

Availability

%

62.5%

76.78%

83%

P

Performance Rate%

93.8%

97.85%

98%

P

Quality products Rate%

92.2%

99.46%

99.3%

P

Number of breakdowns

Breakdowns/year

44

116PMTBF

Hour

166775

PMTTR

Hour

2.5

1.3

1.3Q

Number of customer complaints

Number/year

110Q

In-line defect rate (scrap)

%

8.4%

0.43%

0.3%

Q

In-line defect rate (rework)

%

ND

4.3%

3%

C

Fixed cost

USD/Kg

0.96

1.86

1.63

D

Production Lead Time Cooked

Days

1182

92

D

Production Lead Time Matured

Days

45121

142

D

Delivery performance

%

83%

98%

99%

S

Safety Index

Accidents per
1,000,000 operator
hours

31.9

10M

Number of employee sugestions

Number/year

1612481450

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