1 企业概要Company, Plant/Factory Profile
1.1 君乐宝乳业集团成立于 1995 年，28 年来始终专注于奶业发展，为消费者提供健康、营养、安全的乳制品。农业产业化国家重点龙头企业、国家高新技术企业、国家乳品研发技术分中心。 2015 年君乐宝所有液态工厂通过欧洲 BRC
食品安全全球标准 A+级认证，奶粉工厂通过 BRCAA+认证，成为全球第一家通过AA+认证的奶粉企业。
经过 28 年的发展，自建牧场 17 家，现代化生产基地 21 个，拥有员工 1.4 万余名是河北省最大乳品企业。
1.1 Junlebao Dairy Group was established in 1995. For 28 years,
Junlebao Dairy Group has always focused on the development of dairy
industry, providing consumers with healthy, nutritious and safe dairy
products. National key leading enterprise of agriculturalindustrialization, national high-tech enterprise, national dairy
research and development technology sub center. In 2015, all liquid
factories of Junlebao passed the European BRC Global Food Safety
Standard A+certification, and the milk powder factory passed theBRCAA+certification, becoming the world's first milk powder
enterprise to pass the AA+certification.
After 28 years of development, it is the largest dairy enterprisein Hebei Province with 17 self built pastures, 21 modern production
bases and more than 14000 employees.
1.2 威县君乐宝乳业有限公司位于河北省邢台市威县，隶属于君乐宝乳业集团鲜奶事业部，总占地 106.71 亩，设计年产能 31.2 万吨。整体项目含有两个主体车间，一车间总投资约 4.3 亿元 ，日生产能力 455 吨 ，于 2019 年 3 月正式投产；二车间总投资 2 亿，日生产能力 320 吨，于 2021 年 8 月正式投产。
1.2 Weixian Junlebao Dairy Co., Ltd., located in Weixian County,
Xingtai City, Hebei Province, is subordinate to the Fresh MilkBusiness Department of Junlebao Dairy Group, with a total area of
106.71 mu and a design annual capacity of 312000 tons. The overall
project consists of two main workshops. The total investment of thefirst workshop is about 430 million yuan, and the daily production
capacity is 455 tons, which will be officially put into operation inMarch 2019; The total investment of Workshop II is 200 million, witha daily production capacity of 320 tons, and it will be officially
put into operation in August 2021.
1.3 威县君乐宝乳业有限公司以悦鲜活产品等为主打品牌。产品分为悦鲜活 2
个系列，10 个品项，生产规格有瓶装、袋装，采用 159°C 0.09S 巴氏奶瞬时杀菌工艺，4 条袋装生产线日生产能力 80 吨，3 条瓶装生产线日生产能力 440

吨；学生奶 2 个系列，7 个品项，生产规格为盒装，采用 137°C 4S 灭菌乳杀
菌工艺，4 条产品生产线日生产能力 255 吨。
1.3 Weixian Junlebao Dairy Industry Co., Ltd. takes Yue FreshProducts as its main brand. The products are divided into 2 series
and 10 items of Yuexianhuo. The production specifications include
bottle and bag. The instantaneous pasteurization process of 159 ° C
0.09S is adopted. The daily production capacity of 4 bagged
production lines is 80 tons, and that of 3 bottled production lines
is 440 tons; There are 2 series and 7 items of student milk. The
production specification is boxed. The sterilization process of137 ° C 4S sterilized milk is adopted. The daily production capacityof 4 product production lines is 255 tons.
工厂正式员工 430 人，直接人工占比 81%，大专及以上学历占比 47%，司龄3 年以上员工占比 75%，40 岁以下占比 83%，人员学历普遍较高属于一个年轻的生产团队，学习能力较强，容易接受新的管理理念。
There are 430 regular employees in the factory, 81% of whom aredirect workers, 47% of whom are college graduates or above, 75% ofwhom are over 3 years old, and 83% of whom are under 40 years old.
The employees are generally highly educated and belong to a young
production team with strong learning ability and are easy to accept
new management concepts.
2. 制造改善里程碑
Milestone on the Journey of Manufacturing Excellence
2.1 2019 年 8 月公司运营引入 TPM 理念，2020 年 4 月开始深入开展 TPM 活动，2021 年 1 月全面启动 TPM 活动：DMS 日常管理系统、5S 现场管理、 9 大支柱（FI\AM\PM\QM\EM\ET\SH\ENV\OM-SC）管理，开始改善活动，塑造工厂改善氛围，提升全员改善意识;
In August 2019, the company introduced the TPM concept into itsoperations. In April 2020, it began to carry out TPM activities indepth. In January 2021, it will fully launch TPM activities: DMS
daily management system, 5S on-site management, and nine pillar (FIAM PM QM EM ET SH ENV OM-SC) management. It will start to improve
activities, shape the factory improvement environment, and enhance
the awareness of all employees;
2.2 2019 年 3 月 HACCP 认证，2020 年 12 月引进 BRCGS 系统并认证，从生产过程质量控制，质量管理体系搭建，质量文化塑造，专注产品品质提升；HACCP certification in March 2019, BRCGS system introduced andcertified in December 2020, focusing on product quality improvementfrom production process quality control, quality management systemestablishment, quality culture shaping;
2.3 从 2019 年 8 月到 2020 年 4 月自主推进 TPM 项目，成立 TPM 委员会、识别工厂短板、开展了一些改善项目、没有外部机构专业老师辅导，推进效果不明显；From August 2019 to April 2020, we independently promoted the TPM
project, established the TPM committee, identified the factory'sweaknesses, carried out some improvement projects, and did not havethe guidance of professional teachers from external institutions, sothe promotion effect was not obvious;
2.4 2020 年 4 月份举行了 TPM 启动大会，由深圳大野咨询公司（C&KConsultancy Co.Ltd.）邱老师顾问团队辅导推进，TPM 被正式引入，全面展
开；
In April 2020, the TPM kick-off meeting was held, which wasguided and promoted by the consulting team of Mr. Qiu from Shenzhen
C&K Consultancy Co. Ltd., and TPM was formally introduced and fullylaunched;
2.5 2023 年 12 月威县公司高分通过 TPM 优秀奖 A 类审核，235 我们争取获
得 TPM 优秀奖 A 类继续奖，继续倡导全员参与改善，力争在 2029 年获得特别奖，努力实现成为“打造世界级高端鲜奶制造引领者”的愿景。
In December 2023, our company in Weixian passed the TPM ExcellenceAward A-class review with high scores. We strive to win the TPM
Excellence Award A-class Continuing Award and continue to advocate
for all employees to participate in improvement. We strive to win a
special award in 2029 and strive to become a leader in creatingworld-class high-end fresh milk manufacturing.
3. 工厂获益
Benefits Achieved
3.1 自从 2019 年引入 TPM 以来，工厂设备综合效率提升明显、设备故障率、小停机次数、产品不良、市场投诉数量等指标有明显的下降，人员改善意识和改善能力得到了提升；
Since the introduction of TPM in 2019, the comprehensive
efficiency of plant equipment has improved significantly, theequipment failure rate, the number of small downtime, the number ofdefective products, the number of market complaints and otherindicators have decreased significantly, and the awareness andability of personnel to improve have been improved;
3.2 通过 TPM 推进，极大的提高了公司改善氛围，逐步形成了支柱和职能部
门之间的协作，不断的促进损失的持续减少，追求卓越，为公司持续的发展提供基本的运营保障。
Through TPM promotion, the company has greatly improved theatmosphere, gradually formed the cooperation between the pillar andfunctional departments, constantly promoted the continuous reductionof losses, pursued excellence, and provided basic operational
guarantee for the company's sustainable development.
4.改善关键项目
Key of our Manufacturing Excellence
在 TPM 推进过程中，推行克朗斯瓶线快速切换改善项目，成立改善小组，由TPM 项目组组织小组成员进行检讨，原因分析、制定措施、改善实施验证等活动，经过不断的改善，目前共优化换型时间 152 分钟按 450 产品来算，可以增加产能 25 吨/天；从换型损失的现状来看，改善效果良好，后期会持续进行改善，同时计划扩展到其他产线，通过不断的努力，持续进行改进，实现其他产
线达到同等水平。
In the process of TPM promotion, the Krones bottle line fastswitching improvement project was promoted, and an improvement teamwas established. The TPM project team organized the team members toreview, analyze the causes, develop measures, and verify theimplementation of improvement. After continuous improvement, a totalof 152 minutes of optimized transformation time is calculated as 450
products, and the capacity can be increased by 25 tons/day; From thecurrent situation of model change loss, the improvement effect isgood, and will continue to improve in the later period. At the sametime, it is planned to expand to other production lines, and throughcontinuous efforts, continue to improve, so that other productionlines can reach the same level.
5. Achievement Record

2023 TPM Award -Achievement Sheet君乐宝乳业集团股份有限公司

CompanyJunlebao Dairy Group CO., LTD威县君乐宝乳业有限公司

Plant name

Weixian Junlebao Dairy Co., Ltd构建精益体系、导入精益方法、打造精益流程、发展精益文化

TPM Slogan/Objectives

Build a lean system, introduce lean methods, create lean processes, and develop leanculture

Year when TPM activity started

2019-08-01

Year of benchmarking

2020-04-01
Kick off/TPM

Category

Index

Unit

StartedActual Status

Actual Status

Actual Status

2020

2021

2022

2023

Cases/ year

0100

Cases/ year

0000

Ton/year

70447.7112068.1146,488.06

183760.55%

63.95%

67.54%

72.71%

76.94%(Calculation Formula)(or last timeawarded)

Enter the year →Number of workS

related accidents
requiring days off work
Number of work-S

related accidents not
requiring days off work

P

Annual production
OEE

P(or Overall Plant
Efficiency)

P

Availability%

75.30%

77.20%

80.50%

84.01%

P

Performance Rate%

85.70%

88.23%

90.90%

92.10%P

Quality Products Rate%

99.10%

99.16%

99.37%

99.45%

P

failure rate%

4.95%

1.64%

1.47%

0.73%

PMTBFHours

47.39

58.09

79.50

156.68PMTTR

minutes

70.67

68.28

60.50

37.62

Times/100 tons

2.91

1.2

0.51

0.35%

0.60%

0.52%

0.33%

0.23%

893.44797.29750

QQ

Number of customer
complaints
In-line defect rate(scrap)C

Cost index

RMB yuan/ton

D

Production Lead timehour

95

73

54

46

D

Delivery performance%

97.50%

98.20%

99.83%

99.02%

0000

Number ofS

Frequency rate

occupational
accidents withleave for 1 000
000 worked hours

M

Number of Employee
Suggestions

Number/year

309846

20123427