Site Overview & 5 S
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Site Overview & 5 S

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Overview of plant and an update on 5S progress

Overview of plant and an update on 5S progress

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Site Overview & 5 S Site Overview & 5 S Presentation Transcript

  • Welcome to LITTLEBOROUGH Site Overview – 5S
  • Littleborough Location LITTLEBOROUGH HADDENHAM
  • Factory – Plan View Whitelees Rd Freehold land New Mill St Stockton St
  • Factory Details
    • Whitelees Road Factory Footprint of 8000 m 2
    • Total Site area of 30000 m 2
    • Whitelees Road site produces all glass jars &
    • plastic container packs, plus Ultrakan products
    • 24/5 shift pattern (24/6 during peak months)
    • 200 Operations employees
      • + seasonal requirements
    • Total Site area of 6000 m 2
    • New Mill Street Factory Footprint of 4000 m 2
    • New Mill Street site predominantly produces Dip Pots, Sachets and flexible packs (pouches, bag-in-box).
    • 24/5 shift pattern (24/6 during high demand periods)
    • 90 Operations employees
      • + seasonal requirements
  • Warehouse Details
    • Stockton Street Warehouse Footprint of 5000m 2
    • Total Site area of 12000m 2
    • Racking spaces for 3200 pallets
    • Stockton Street stores all packaging (glass jars,
    • plastic bottles, Ultracans, top-film, base web,
    • sachet laminate, boxes) and ambient
    • ingredients (powders, liquids)
    • 24/5 shift pattern (24/6 during peak months)
    • 14 Operations employees
  • SKU Count Tonnage 1200T/wk Finished Goods SKU’s 330 Packaging formats 35 Ingredient SKU’s 320 Packaging SKU’s 550
  • 5S At Littleborough
    • Poor GMP Scores
    • Production & Process Areas in need of a Facelift
    • No Ownership of Equipment or Working Area
    • Poor Organisation of Space
    • “ Black Holes” across the sites
    Starting Point
    • Project Brief
      • Build a 5s Workshop
      • Improve the Working Environment
      • Facilitate in Organising Work Areas
    • Used an Existing Workshop Presentation
      • Presentation Used by Nigel in the Past
      • Presentation Branded to a McCormick Style by Facilitator
    Starting Point
    • Present 5s Overview to All Managers & Team Leaders
    • Pre-Brief The Area Leaders
    • Understand The Area/s to be Targeted
    • Send Out Invitations & 5s Overview Booklet
    • Group & Team Leader Participation in Workshops
    Before The Workshop
    • Pre-Training Information Booklet for Attendees – Written & Produced In House
    Before The Workshop
    • Introduction / Overview of 5s
    • 1 st 5s Audit
    • Create A Vision
    • SORT
    • SET
    • SHINE
    • STANDARDISE
    • SUSTAIN
    The Workshop
    • 1 st Audit
      • Carry Out a Detailed Audit of The Area
      • Complete a 5s Audit Sheet
    • Create A Vision
      • Categorise The Possible Improvements To Be Made
          • Current Conditions / Desired Conditions
          • Making Operations Easier
          • Action Plan
        • Safety
        • Quality
        • Equipment Maintenance
        • Efficiency Of Work
        • Inventory Levels
        • Information Sharing
    The Workshop
    • Sort
      • Red Tag Technique
      • Clear Area
      • Red Tag Area
    • Engineers Red Tag Area - WLR
    The Workshop
    • BEFORE SORT
    • AFTER SORT
    • NMS Dry Prep
    The Workshop
    • SET
      • Organise Area To Suit
      • 30 Second Rule
      • Mark & Label Areas
        • Equipment
        • Storage
        • WIP
        • Inventory
    The Workshop
    • SHINE
      • Inspection
      • Early Detection
      • Create Shine Standard
    The Workshop
    • STANDARDISE
    • SUSTAIN
      • Overview of the final 2s
    The Workshop
  • The Workshop Each Certificate Personal to Recipient, Individually Signed & Copy Displayed
    • Audits
    • Newsletters
    • 5s Ideas
    • Action Plans
    Post Workshop
    • Audits Carried Out By Trained Audit Team
    Post Workshop
  • Post Workshop
  • Post Workshop Comments
    • Complete Standardise & Sustain Training
    • Planned Move of Equipment – Area 5S
    Next Steps
  • Equipment Moves
    • Set a Budget for 5S Improvements
      • Re-Organisation of Work Areas
      • Improvement Ideas
    • Complete Engineering Areas 1 st
      • If Engineers “Buy In” Improvements Will Be Easier To Drive
    • Plan Final 2S Sessions
      • Commit to Completing The Workshop
    What Would We Do Better?
    • Awards & Recognition
      • Best Audit Score
      • Most Improved
      • Stuck In The Mud
    What Would We Do Better?
    • Commit Resources and Plan
      • All Shifts On The Workshop
      • Planned Areas To Be Shutdown
      • Involvement From All Levels
    • Own Facilitator
      • Ownership of 5S Philosophy
      • Consistent Approach
      • Understanding Of Site
    What Did We Do Right?
    • Engineers On Every Workshop
      • Break Down Barriers
      • Able To Repair Problems Immediately
    • Momentum
      • Complete Areas In Quick Succession
      • Concentrate On The 1 st 3S
      • Stops Stagnation
      • Everyone Can See The Commitment
    What Did We Do Right?
  • Visual Management Planning The Workshops
  • Visual Management Branding The 5S Philosophy
  • Visual Management Branding The 5S Philosophy
    • Quantity Control
      • Control of Stock Levels
      • Reminder to Re-Stock
    Visual Management
    • Use of Shadow Boards
      • Controls Equipment
      • Missing Equipment Identified
    Visual Management
  • Improvements
    • Rolled Out 5S in our South African Dry Plant (Midrand)
    • Blue Room
    • Rainbow Room
    South Africa
    • Engineering Area One Of The 1 st To Embrace 5S
    South Africa
  • South Africa
    • Within 3 Months All Dry Plant Employees Completed a 5S Workshop
    • Interest From Other Sites In The U.S.A., Turkey & China
    South Africa
  • FACTORY TOUR