Laduma Q3 2014

Quarter 3, 2014

LADUMA

SPECIAL EDITION

Supply chain – page 3 Giving support – pages 7-12 Focus on pumps – page 4

ONE TEAM - ONE GOAL !

MESSAGE FROM THE MD Eight months into the year and it is pleasing to see that we have managed to continue the strong performance of the first quarter of 2014. Sales volumes are well ahead of last year and although we are now using higher-priced raw material which has put pressure on margins, overall performance is still ahead of last year at this stage. The focus on supplychain effectiveness is bearing fruit and it is pleasing to see NCP Alcohols and our consultants, Resolve, receiving national recognition for the improvements in this field.

We have started the review of our product and market portfolios in order to optimise best value and the implementation of this is being carefully managed to ensure that the impact of changes we make does not create unnecessary inconvenience for our customers. In my Q1 message I referred to the publishing of the long-awaited mandatory biofuel rules in May. Unfortunately this did not happen and it appears we will have to wait a while longer with no specific date

currently being given by government for publication.

I was privileged to be invited to the 25th anniversary celebrations of our holding company, Alcogroup, in France recently. About 80 people representing more than 20 nationalities attended the event and what struck me was the attitude, enthusiasm and passion for the business and the company shown by those present. Prior to the event we had been asked to describe in not more than three words what the Alcogroup meant to us and the following are some of those words used by those attending: Entrepreneurship; respect; opportunity; family; evolution and collaboration; ambitious; passion, trust, team spirit; fun; experience; teamwork; a chance to grow; challenge; enjoyment; respect.

These are many of the same attributes that makes NCP Alcohols the unique company that it is,and why we are all privileged to part of it.

g

lin Peter Star

Production team rise to the challenge The good news is that there is such a demand for our ethanol from African markets that our plant can hardly keep up.

After awesome production figures were achieved in January and February this year, reality kicked in – along with challenges in the cooling water treatment plant.

However, with Zinhle Mdadane, Production Manager, driving the distilleries hard, and her team responding in unison, it is anticipated that production figures will soon be back up there.

Said Zinhle, “The team knows what is expected of it. I commend them for their dedication and their understanding that getting it right is for the long-term good of all involved.�

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SAFETY is a way of life

Some of the Production team are, from left, front, Ashika Jithoo, Smangele Nzimande and Selby Zungu; middle, Riolyn Moodley and Vicky Singh; and back, Zinhle Mdadane.

Supply Chain Millions saved after department revamp ...

The recent drive to overhaul NCP Alcohols’ supply chain operation is showing excellent initial results; some have even nicknamed the hardworking team “Simply The Best”.

Says André van der Westhuizen, Supply Chain Executive, “Several years ago, we saw that our logistics costs, expressed as a percentage of revenue, were climbing unacceptably.

We brought in consultants who identified two key drivers: accountability and visibility; essentially, we had to make more accurate information available for decision making – which we did partly by introducing new software.

“We also invested in skills development and made other changes, to the extent that we now have a dedicated and committed supply chain team. Congratulations to them. Our logistics costs are heading back down again; last year we saved R4 million, and this year we have saved R2,4 million in logistics costs so far, all without affecting our customer service.

“But it is about more than the money. We operate in a costcompetitive market, and the cost of raw materials is increasing.

On the cover Front cover: Sue Stewart, Receptionist, and Ashraf Moosa, Financial Accountant, get into the spirit of Mandela Day at the nearby Training and Resources in Early Education (TREE). More on page 11.

The Supply Chain Team are, from left, Raj Mothi, Mervin Pillay, Ashley Sathdav, Lee-Anne Ramlall, Andre van der Westhuizen, Faizee Bohda, Romy Hancock, Biddy Harmer, Thembi Sishi, Sibusiso Mthabela and May Khan.

To remain profitable and to ensure the long-term future of our company, we have to be competitive; having a sharp supply chain helps us do that.”

André recently co-presented a paper on the development of our new supply chain department to a recent annual conference of SAPICS, the SA Production and Inventory Control Society.

He said it had been well received, partly because it was a reallife, practical example of what was successfully done.

Team wins achievement award Another ‘Well Done’ to the Supply Chain team. NCP Alcohols/ Tanker Services/ Resolve was one of three be awarded a BRONZE AWARD for RECOGNITION OF ACHIEVEMENT at the recent annual Logistics Achiever Awards for developing a resilient supply chain and reducing transport costs through improved vehicle planning. Said André, “This could not have been achieved without the commitment and dedication of the individuals in the team. It makes me feel proud to be apart of this team. Thank you all. Keep up the excellent work.”

Work safe, play safe

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Improving our environment Historically molasses and CMS (condensed molasses solubles) pumps have had gland-packing seals with drip trays that require constant maintenance and adjustment to the gland follower to minimise minor leaks. Spillages sometimes occur over long weekends when maintenance staff are not available and with changing process conditions.

The first improvement made, was to contain any spillages from molasses and CMS pumps and tanks by bunding each area, and installing an isolation valve.

During the past two years, bunding with isolation valves has been completed on Molasses tank 4, as well as CMS tanks 1 and 2, and CMS receiver tank area. CMS tank 3 bund and isolation valve will be completed by the end of November 2014.

Spillages will be contained and recovered, reducing discharge to effluent.

The next step is to upgrade all molasses and CMS pumps to leak-free double mechanical seals with seal pots using water as a barrier fluid. No more leaks and no more washing down with water!

Conversion of all the pumps will be completed in early 2015.

Top New AE seals double seal chamber.

Middle Molasses Dam magmflo feed pump with double seals and a seal pot. Water is used as a barrier fluid.

Bottom CMS loading mono pump from No.3 bulk storage tank.

Double seal and seal pot installed.

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Report all NEAR MISSES

Oxygen trim commissioned Oxygen trim on Boiler 1 was initiated in projects 2013, but owing to the complexity of integrating SAACKE and WEG communication systems, numerous hurdles had to be overcome. NCPA’s engineering team together with SAACKE and WEG technicians commissioned the oxygen trim during a one-day boiler shutdown on 13 August 2014.

Air-to-fuel ratio is one of the main factors affecting boiler efficiency. Although the ratio is set during commissioning, it tends to drift after a while. Oxygen trim control regulates the air rate to maintain the best combustion conditions at all times.

Louie Pillay, Utilities Manager, says “We are currently monitoring the oxygen trim readings daily and will start verifying fuel savings after two months.”

Carl Freyer, Engineering Manager, says “The greater fuel efficiency and lower carbon emissions

The oxygen sensor which measures the oxygen Carl Freyer – Engineering Manager, Don Pillay content in the fuel gas – Utilities Controller, Matthews Dubazane – existing in the Boiler.

Utilities Controller, Shon Roopnarain, Instrument are because the air- Superintendent, Judy Somers, Electrical fuel ratio is continuously Superintendent, and Louie Pillay, Utilities optimised throughout its Manager, with the oxygen control system at the Boiler Management System panel. range.”

SAFETY: Please report all near misses!

The Safety Representatives at NCP Alcohols play a crucial role in keeping everyone on site out of harm’s way.

happening again, and attend SHE committee meetings with management.

One of their key duties is to do monthly safety inspections for their respective work areas. They are also required to give a safety talk in their area every month, take part in risk assessments, get involved in the investigation if someone has been injured and take steps to prevent the injury from

Says Lorraine Mudaly, SHEQ Manager, “It is vital that EVERYONE, not just Safety Reps, reports near-miss accidents.

Perhaps no one was hurt this time, but if we do not report it, someone could be hurt next time. We know that sometimes people say they are too busy, or it is someone else’s problem, but you should simply tell your manager, your Safety Rep, or supervisor, or submit an electronic report using the Improvement Opportunity system. No one will point a finger at you, and everyone will learn from it. Contractors too should report near misses to their responsible manager.

NCPA goes EAST

“I would like to encourage everyone to be more proactive in safety, and do not be shy to intervene when necessary. Safe work is part of our culture on site; safety belongs to all of us.”

NCP Alcohols recently visited a distillery at one of its suppliers in India, Globus Spirits. Seen in front of the Globus Spirits factory are, from left, Mr Jasbir Singh, Globus Vice-President; Hartmut Nowak, NCPA Associate; Peter Starling, NCPA Managing Director; Mr Shekhar Swarup, Executive Director; Mr Indu B Lal, Senior Adviser, and Mr RK Malik, Senior VicePresident.

The current Safety Representatives on site are: Workshop, Engineering and Stores: Errol Murran Site Logistics: Allan Pillay Boiler House: Mathews Dubazane Admin Building: Faizee Bodha Laboratory: Bala Padayachee Production – Fermentation, Evaporation Plant and Cooling Towers: Rakesh Moona Top and Bottom Distilleries, Vinegar Plant and Effluent: Zwelenkosi Mbhele

WORK SAFE, go home safe

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E R I F

g n i n i a r t

Using extinguishers Fire-extinguisher training took place over a few days in July. According to Kelvin Timm, Fire Officer, these sessions are compulsory for all employees and permanent contractors, and training is provided every year by Dave Kemp.

Dave Kemp (left) giving hands-on training to BCX IT Engineer Ricardo Peter who is navigating his way to extinguishing a staged fire. Yes, we even train permanent contractors.

EMERGENCY PROCEDURES within reach The company’s emergency procedures are now accessible and within reach of everyone on the plant. Our emergency procedure flip charts include: * Evacuation Route and Gas Retreat Areas & Radioactive Sources * Fire * Explosion * Bomb Threat * Toxic Gas Release * Serious Injury or Illness * Mayor Spill * Flooding * Civil Unrest * Armed Robbery * Lightning Strike * Vehicle Accident * Product Recall * Emergency Contacts (Ext. & Int.) * Emergency Services * SHE Representatives * Floor Marshals * Emergency Alarms

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Errol Murran, Mechanical Fitter, seen here with Lorraine Mudaly, SHEQ Manager, at one of the ingenious emergency procedures boards he designed and manufactured for the company using mainly recycled material.

Choose safety for your family

We help fight crime Rodgers Niranjan, Procurement Manager, standing centre, hands over crime-fighting equipment to Douglas Naidoo, chairperson of our neighbouring Greenwood Park Community Police Forum (CPF), Sector 3 sub forum. Also seen are, front from left, Sipho Shezi, community rep, Robin Candy, chairman of Greenwood Park CPF main forum, and Sifiso Zondi, community rep; and back, Lt Elvis Naidoo and Capt D Mnguni, both of SAPS, Steven Kweyama, community rep, and Deochand Ganesh, DA city councillor.

NCP Alcohols recently donated 30 sets of LED torches, whistles and reflective vests to Street Committees in the Kenville/Sea Cow Lake/ Springfield Park areas. The equipment is to be used to combat crime.

Speaking at the handover, Col M Mngadi, Station Commissioner Greenwood Park SAPS, encouraged the communities to form local structures who could then liaise with the police, and to attend structures meetings.

He said the police wanted to engage with the poor and assist them, but it was essential to work together. The community, for their part, should report drug dealers and people selling stolen property in their areas; they should report child abuse; and they should attend CPF meetings.

He also urged community members to do street patrols using the new equipment, but not to take the law into their own hands.

Shaping their futures

Supporting youngsters NCP Alcohols recently had the opportunity to once again support Girls and Boys Town’s Tongaat Youth Development Centre by sponsoring the centre with new bed linen and shower doors. The partnership between NCP Alcohols and Girls and Boys Town goes back a few years.

Gary Bregovits, Operations Executive, with some of the bedding donated by NCP Alcohols.

NCP Alcohols is the proud sponsor of Bongiwe Manyathi, the supervisor of the S’bongile Crèche in Briardene, toward her Early Childhood Development (ECD) Practitioner Level 4 training qualification.

This training sponsorship ensures that Bongiwe and the children of S’bongile Crèche benefit from the quality ECD training received at TREE, a leading ECD training and resources centre.

NCP Alcohols’ Financial Executive, Mark Norton-Amor, visited the crèche to surprise Bongiwe with the good news of her scholarship. Mark said that NCP Alcohols was very proud to be a part of shaping the future of young children in their area. They are seen here with Terry Kass, Marketing and Income Development Manager, right.

Be safe, NOT SORRY

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Keeping close to customers Elaine Wilson, Marketing Manager, and Jane Ngwabe, Sales Representative, celebrated Women’s Day on 14 August at the Coschem 9th Annual Ladies Day. NCP Alcohols is a member of the Cosmetics Toiletries and Fragrance Association of South Africa, and most of the company’s cosmetic customers in the Gauteng region also attended this event.

According to Jane, it was a useful opportunity to liaise with them and others in the cosmetics and pharmaceutical industry.

NCPA-supported dance group shines FLATFOOT DANCE COMPANY recently performed for two nights at the prestigious 16th annual JOMBA! Contemporary Dance Festival, the second-largest dance festival in Africa!

As one of only five invited companies, FLATFOOT presented a work called “HOPE”. “HOPE” was choreographed by Lliane Loots and featured the six resident FLATFOOT dancers: Jabu Siphika, Zinhle Nzama, Julia Wilson, Sifiso Majola, Tshediso Kabulu and Sifiso Khumalo.

The work was also a collaboration with local Durban singer and songwriter Shannon Hope, whose own brand of torch songs has seen her being named one of South Africa’s top 200 most influential young people. “HOPE” was a soft and lyrical connection between Shannon’s own music (played live on stage) and the FLAFTOOT dancers.

NCP Alcohols staff were offered tickets to see the work and FLATFOOT was delighted to host them at the JOMBA! event held at the Sneddon Theatre on 29 and 30 August.

FLATFOOT remains deeply proud of a four-year partnership with NCP Alcohols who assist in supporting the huge range of dance education and dance development work being done in KZN.

Photography by VAL ADAMSON

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SAFETY is my responsibility

Putting NCPA ‘out there’ .....

Seen assisting Sthembile Maferesane, a high-school learner, and Sanele Mhlongo, an electrical engineering student at DUT, at the World of Work stand are, from left, Nikita Singh, Lumeshni Govender and Jivenika Sewpersadh.

Wellness checked

The NCP Alcohols annual Wellness Day, held this year on 23 April, provides employees with a chance to better their health.

A check-up involving four quick tests was done, and there was an online questionnaire to help employees learn about their health; this is the first step to improving it, according to experts at Discovery Health.

The wellness checks took about 30 minutes, after which employees could learn more about their health status. The company sponsored employees that are not members of Discovery Health to take the wellness test and every person on site including contractors had the opportunity to undergo sponsored HCT/HIV counselling and testing on the day.

Seen having a blood pressure test is Les Appalsamy.

NCP Alcohols took part in an annual careers fair, the World of Work (WOW), held at the Durban University of Technology Sports Centre over two days recently. During the exhibition, preferred employers from across KZN exhibited their companies in an effort to attract top employees or in-service students.

Managing the NCPA exhibit was Lumeshni Govender, Process Technician, and she believes that “it begins with acknowledging that the future of SA is the youth and that this exhibition is an opportunity for students to interact with some of SA’s top companies while the companies showcase what they are all about.”

NCP Alcohols received 385 CVs this year and also rolled out Skills Map, the company’s on-line careers portal on their website.

MD Peter Starling thanked all the employees involved in preparing, hosting and dismantling the NCP Alcohols stand at the career fair. In his message Starling said, “NCP Alcohols traditionally boxes above its weight in the KZN business environment and it is great to hear how enthusiastically the students responded to your efforts. Your involvement and contribution not only puts NCPA ‘out there’, but also makes people aware of what kind of company we are. Students may not know it, but all workplaces are not equal; your attitude helps them see how unique we are.”

The WOW is all about career opportunities, industry requirements and career-path advice, and is the ideal time for companies to acquire ‘la crème de la crème’ for the future of their organisation.

According to Govender, the WOW was very exciting, with an extra splurge of publicity for NCPA when she was interviewed by Radio DUT. The fair also highlighted a number of different fields of study that could be of great interest and benefit to NCPA as we have something unique to offer; one such field is Environmental Health OHS & Industrial Engineering.

Your safety is in your hands

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Helping to integrate young disabled into society People with disabilities have an important role to play and can make a positive contribution in the workplace. It is generally found that a person with a disability develops into a well-adjusted, productive worker in an atmosphere of acceptance, co-operation and goodwill.

NCP Alcohols currently supports two learners at I Can, a place of learning that focuses not only on providing learners with a qualification but also looks at building them up to become selfsufficient independent individuals who are employable at the end of their learnership programme.

I Can offers three qualifications: Life Skills, and Hygiene & Cleaning on an NQF Level 1 for learners with an intellectual disability, and Business Practice NQF

Supporting local stars

Reaching out to the unwell

Nomvula Samantha Nzuza left, and Khanyisile Princess Mfolozi.

Level 1 & 2 for learners with a physical disability.

NCP Alcohols’ learners Princess Khanyisile and Samantha Nomvula are at The Durban North Academy, I Can’s head office, with 86 other learners.

Princess and Nomvula are currently completing a Life Skills qualification and are currently on module 5, ‘Security in and around the house’, where they learn the importance of identifying security features not only around the house but also around the academy.

Joining two oncology patients (front row) at a Look Good Feel Better session held during August 2014 at the Umhlanga Oncology Centre are volunteers Dot Koekemoer and Magda du Plooy, Elaine Wilson – Marketing Manager at NCP Alcohols, and Loren Fergusen – LGFB Team Leader for Umhlanga Oncology Centre.

New branded kit donated

Sponsoring Thembeka

Seen here with the Shooting Stars is Project Manager Rydal Spavins from the Durban Rotary Club.

The Shooting Stars, a development soccer team from KwaMashu, was sponsored by NCP Alcohols during an Action Soccer event held on Saturday, 13 September to raise funds in support of the Natal Settlers Home for much needed wheelchairs, as well as a rural vegetable garden feeding scheme managed by the Durban Rotary Club.

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Littering is TRASHY

NCP Alcohols United Football Club (NUFC) recently received their new soccer kits. Seen here showing off the team’s new colours is Tasvir Ramouthar, Electrical Engineering In-Service Trainee.

Thembeka Madlala is a Grade 3 learner at the Fulton School for the Deaf, sponsored by NCP Alcohols.

Her mid-year progress report states that her father lost some of his fingers in an accident last year, exacerbating the family’s financial situation. Thembeka is described as a ‘friendly and diligent young girl who loves her teachers and friends, and is a great help in the classroom and in the hostel where she enjoys assisting the younger boarders.’

Acting to honour Mandela To mark International Mandela Day, NCP Alcohols employees dedicated 67 minutes of their time on 16 July to planting a vegetable garden at the nearby Training and Resources in Early Education (TREE).

EAT, SLEEP and RECYCLE

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Safety is MY RESPONSIBILITY