Site Overview & 5 S

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Overview of plant and an update on 5S progress

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Site Overview & 5 S

  1. 1. Welcome to LITTLEBOROUGH Site Overview – 5S
  2. 2. Littleborough Location LITTLEBOROUGH HADDENHAM
  3. 3. Factory – Plan View Whitelees Rd Freehold land New Mill St Stockton St
  4. 4. Factory Details <ul><li>Whitelees Road Factory Footprint of 8000 m 2 </li></ul><ul><li>Total Site area of 30000 m 2 </li></ul><ul><li>Whitelees Road site produces all glass jars & </li></ul><ul><li>plastic container packs, plus Ultrakan products </li></ul><ul><li>24/5 shift pattern (24/6 during peak months) </li></ul><ul><li>200 Operations employees </li></ul><ul><ul><li>+ seasonal requirements </li></ul></ul><ul><li>Total Site area of 6000 m 2 </li></ul><ul><li>New Mill Street Factory Footprint of 4000 m 2 </li></ul><ul><li>New Mill Street site predominantly produces Dip Pots, Sachets and flexible packs (pouches, bag-in-box). </li></ul><ul><li>24/5 shift pattern (24/6 during high demand periods) </li></ul><ul><li>90 Operations employees </li></ul><ul><ul><li>+ seasonal requirements </li></ul></ul>
  5. 5. Warehouse Details <ul><li>Stockton Street Warehouse Footprint of 5000m 2 </li></ul><ul><li>Total Site area of 12000m 2 </li></ul><ul><li>Racking spaces for 3200 pallets </li></ul><ul><li>Stockton Street stores all packaging (glass jars, </li></ul><ul><li>plastic bottles, Ultracans, top-film, base web, </li></ul><ul><li>sachet laminate, boxes) and ambient </li></ul><ul><li>ingredients (powders, liquids) </li></ul><ul><li>24/5 shift pattern (24/6 during peak months) </li></ul><ul><li>14 Operations employees </li></ul>
  6. 6. SKU Count Tonnage 1200T/wk Finished Goods SKU’s 330 Packaging formats 35 Ingredient SKU’s 320 Packaging SKU’s 550
  7. 7. 5S At Littleborough
  8. 8. <ul><li>Poor GMP Scores </li></ul><ul><li>Production & Process Areas in need of a Facelift </li></ul><ul><li>No Ownership of Equipment or Working Area </li></ul><ul><li>Poor Organisation of Space </li></ul><ul><li>“ Black Holes” across the sites </li></ul>Starting Point
  9. 9. <ul><li>Project Brief </li></ul><ul><ul><li>Build a 5s Workshop </li></ul></ul><ul><ul><li>Improve the Working Environment </li></ul></ul><ul><ul><li>Facilitate in Organising Work Areas </li></ul></ul><ul><li>Used an Existing Workshop Presentation </li></ul><ul><ul><li>Presentation Used by Nigel in the Past </li></ul></ul><ul><ul><li>Presentation Branded to a McCormick Style by Facilitator </li></ul></ul>Starting Point
  10. 10. <ul><li>Present 5s Overview to All Managers & Team Leaders </li></ul><ul><li>Pre-Brief The Area Leaders </li></ul><ul><li>Understand The Area/s to be Targeted </li></ul><ul><li>Send Out Invitations & 5s Overview Booklet </li></ul><ul><li>Group & Team Leader Participation in Workshops </li></ul>Before The Workshop
  11. 11. <ul><li>Pre-Training Information Booklet for Attendees – Written & Produced In House </li></ul>Before The Workshop
  12. 12. <ul><li>Introduction / Overview of 5s </li></ul><ul><li>1 st 5s Audit </li></ul><ul><li>Create A Vision </li></ul><ul><li>SORT </li></ul><ul><li>SET </li></ul><ul><li>SHINE </li></ul><ul><li>STANDARDISE </li></ul><ul><li>SUSTAIN </li></ul>The Workshop
  13. 13. <ul><li>1 st Audit </li></ul><ul><ul><li>Carry Out a Detailed Audit of The Area </li></ul></ul><ul><ul><li>Complete a 5s Audit Sheet </li></ul></ul><ul><li>Create A Vision </li></ul><ul><ul><li>Categorise The Possible Improvements To Be Made </li></ul></ul><ul><ul><ul><ul><li>Current Conditions / Desired Conditions </li></ul></ul></ul></ul><ul><ul><ul><ul><li>Making Operations Easier </li></ul></ul></ul></ul><ul><ul><ul><ul><li>Action Plan </li></ul></ul></ul></ul><ul><ul><ul><li>Safety </li></ul></ul></ul><ul><ul><ul><li>Quality </li></ul></ul></ul><ul><ul><ul><li>Equipment Maintenance </li></ul></ul></ul><ul><ul><ul><li>Efficiency Of Work </li></ul></ul></ul><ul><ul><ul><li>Inventory Levels </li></ul></ul></ul><ul><ul><ul><li>Information Sharing </li></ul></ul></ul>The Workshop
  14. 14. <ul><li>Sort </li></ul><ul><ul><li>Red Tag Technique </li></ul></ul><ul><ul><li>Clear Area </li></ul></ul><ul><ul><li>Red Tag Area </li></ul></ul><ul><li>Engineers Red Tag Area - WLR </li></ul>The Workshop
  15. 15. <ul><li>BEFORE SORT </li></ul><ul><li>AFTER SORT </li></ul><ul><li>NMS Dry Prep </li></ul>The Workshop
  16. 16. <ul><li>SET </li></ul><ul><ul><li>Organise Area To Suit </li></ul></ul><ul><ul><li>30 Second Rule </li></ul></ul><ul><ul><li>Mark & Label Areas </li></ul></ul><ul><ul><ul><li>Equipment </li></ul></ul></ul><ul><ul><ul><li>Storage </li></ul></ul></ul><ul><ul><ul><li>WIP </li></ul></ul></ul><ul><ul><ul><li>Inventory </li></ul></ul></ul>The Workshop
  17. 17. <ul><li>SHINE </li></ul><ul><ul><li>Inspection </li></ul></ul><ul><ul><li>Early Detection </li></ul></ul><ul><ul><li>Create Shine Standard </li></ul></ul>The Workshop
  18. 18. <ul><li>STANDARDISE </li></ul><ul><li>SUSTAIN </li></ul><ul><ul><li>Overview of the final 2s </li></ul></ul>The Workshop
  19. 19. The Workshop Each Certificate Personal to Recipient, Individually Signed & Copy Displayed
  20. 20. <ul><li>Audits </li></ul><ul><li>Newsletters </li></ul><ul><li>5s Ideas </li></ul><ul><li>Action Plans </li></ul>Post Workshop
  21. 21. <ul><li>Audits Carried Out By Trained Audit Team </li></ul>Post Workshop
  22. 22. Post Workshop
  23. 23. Post Workshop Comments
  24. 24. <ul><li>Complete Standardise & Sustain Training </li></ul><ul><li>Planned Move of Equipment – Area 5S </li></ul>Next Steps
  25. 25. Equipment Moves
  26. 26. <ul><li>Set a Budget for 5S Improvements </li></ul><ul><ul><li>Re-Organisation of Work Areas </li></ul></ul><ul><ul><li>Improvement Ideas </li></ul></ul><ul><li>Complete Engineering Areas 1 st </li></ul><ul><ul><li>If Engineers “Buy In” Improvements Will Be Easier To Drive </li></ul></ul><ul><li>Plan Final 2S Sessions </li></ul><ul><ul><li>Commit to Completing The Workshop </li></ul></ul>What Would We Do Better?
  27. 27. <ul><li>Awards & Recognition </li></ul><ul><ul><li>Best Audit Score </li></ul></ul><ul><ul><li>Most Improved </li></ul></ul><ul><ul><li>Stuck In The Mud </li></ul></ul>What Would We Do Better?
  28. 28. <ul><li>Commit Resources and Plan </li></ul><ul><ul><li>All Shifts On The Workshop </li></ul></ul><ul><ul><li>Planned Areas To Be Shutdown </li></ul></ul><ul><ul><li>Involvement From All Levels </li></ul></ul><ul><li>Own Facilitator </li></ul><ul><ul><li>Ownership of 5S Philosophy </li></ul></ul><ul><ul><li>Consistent Approach </li></ul></ul><ul><ul><li>Understanding Of Site </li></ul></ul>What Did We Do Right?
  29. 29. <ul><li>Engineers On Every Workshop </li></ul><ul><ul><li>Break Down Barriers </li></ul></ul><ul><ul><li>Able To Repair Problems Immediately </li></ul></ul><ul><li>Momentum </li></ul><ul><ul><li>Complete Areas In Quick Succession </li></ul></ul><ul><ul><li>Concentrate On The 1 st 3S </li></ul></ul><ul><ul><li>Stops Stagnation </li></ul></ul><ul><ul><li>Everyone Can See The Commitment </li></ul></ul>What Did We Do Right?
  30. 30. Visual Management Planning The Workshops
  31. 31. Visual Management Branding The 5S Philosophy
  32. 32. Visual Management Branding The 5S Philosophy
  33. 33. <ul><li>Quantity Control </li></ul><ul><ul><li>Control of Stock Levels </li></ul></ul><ul><ul><li>Reminder to Re-Stock </li></ul></ul>Visual Management
  34. 34. <ul><li>Use of Shadow Boards </li></ul><ul><ul><li>Controls Equipment </li></ul></ul><ul><ul><li>Missing Equipment Identified </li></ul></ul>Visual Management
  35. 35. Improvements
  36. 36. <ul><li>Rolled Out 5S in our South African Dry Plant (Midrand) </li></ul><ul><li>Blue Room </li></ul><ul><li>Rainbow Room </li></ul>South Africa
  37. 37. <ul><li>Engineering Area One Of The 1 st To Embrace 5S </li></ul>South Africa
  38. 38. South Africa
  39. 39. <ul><li>Within 3 Months All Dry Plant Employees Completed a 5S Workshop </li></ul><ul><li>Interest From Other Sites In The U.S.A., Turkey & China </li></ul>South Africa
  40. 40. FACTORY TOUR

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