1. Current/New PAT Projects
• Change Overs
• PM Completion
• Metal sticks
• Bulk Management
• Temp Orientation
• Operations
Consistency/Mentoring
• Forecasting
• Marsh printer holds
Old PAT projects will be
closed and tracked as
we move into the new
ones.
2. Vibratory Waste Tracking
Vibratory improvement waste in dollars line 2
$1,345.18
$733.00
$2,640.00
$2,374.15
$1,234.97
$2,039.40
$1,482.17
$932.00
$979.53
$697.31
$2,763.49
$6,285.06
$2,867.52
$2,530.71
$-
$1,000.00
$2,000.00
$3,000.00
$4,000.00
$5,000.00
$6,000.00
$7,000.00
Aug
Sept
O
ct
N
ov
D
ec
Jan
Feb
M
arch
April
M
ay
June
July
Aug
Sept
3. Average waste per run
64657744 6425456
0
200
400
600
800
1000
1200 Aug
Sept
Oct
Nov
Dec
Jan
Feb
March
April
May
June
July
Aug
Sept
Oct
Runs
avg. per run
Goal to be less
than 300lbs
per run
4. Identify Safety Hazard PAT
Process Action Team
Team Owner: John King Team Name: Identify Safety Hazards
Team Members Current Process Proposed Process
1 John King 1 See attachments 1 See attachments
2 Duane Gagnon 2 2
3 Ronnel Porter 3 3
4 4 4
5 5 5
6 6 6
7 7 7
8 8 8
9 9 9
10 10 10
Metrics Identified to Measure Effectiveness Goals
1 Total incident rate for plant 1 Identify safety hazards
2 Before & After pics to identify change 2 Fix safety hazards
3 3
4 4
5 5
5. Current Projects all Complete
• Board replaced in deck at smoking area
–Complete
• Bottom of stairs by casepacker #2 to
have non-slip tape replaced
–Complete
• Eye wash station leaking at base on
Feed station.
– Complete
6. PM Completion PAT
Process Action Team
Team Owner: John King Team Name: PM Completion
Team Members Current Process Proposed Process
1 Duane Gagnon 1 See attachments 1 See attachments
2 Frank Brown 2 2
3 John King 3 3
4 4 4
5 5 5
6 6 6
7 7 7
8 8 8
9 9 9
10 10 10
Metrics Identified to Measure Effectiveness Goals
1 Graphs of PM status, Downtime, & Eff. 1 95% completion
2 2
3 3
4 4
5 5
7. PM Completion vs. Plant Efficiency
Started Aug 14th
07’
PM completion vs. Plant Efficiency
60.0%
65.0%
70.0%
75.0%
80.0%
85.0%
90.0%
95.0%
100.0%
105.0%
Jan Feb Mar Apr May Jun Jul Aug Sep Oct
PM's
Efficiency
Goal is
95% PM
completion
8. PM Completion vs. Downtime
PM's
93.0%
84.0%
90.0%91.0%
79.0%
91.0%
68.0%
95.5%
91.6%89.0%
60.0%
65.0%
70.0%
75.0%
80.0%
85.0%
90.0%
95.0%
100.0%
Jan Feb Mar Apr May Jun Jul Aug Sep Oct
PM's
Down Time in Minutes
3270 3168
4900
3435
5972
4895
5575
7006
3729
3395
0
1000
2000
3000
4000
5000
6000
7000
8000
Jan Feb Mar Apr May Jun Jul Aug Sep Oct
Downtime
Goal less
than 3,500
minutes
PAT in effect Aug. 14th
10. Where the team is at
• Team is currently outlining the process and cycle
timing the steps.
• Due to the slow schedule, there has not been
many chances for cycle timing.
• Have identified 3 changes that require no rinse,
and formed a Matrix showing what to rinse on
the items that need a rinse.
• Focus is the time to rinse the former not mixer.
Mixer will be complete and mix ready if Kanbans
are followed.
11. Pareto of rinse down
Rinse steps at former
0.56
3.45
5.36
8.9
10.53
48.45
10
0.36
10.5
10
0.56
50
5
8.5
38
23
58
0 10 20 30 40 50 60 70
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Roll up
hose
Go get
hose
Turn
on
water
4.85 minutes to
rinse the former
12. • 4.85 minutes current rinse time per mach..
– Three longest cycles are non value non
needed.
– Saving time in motion could drop these from
158.45 seconds to 150 seconds or less. (Un-
verified)
– Or 2.5 minutes out of the process.
• 2.5 minutes on line 2 = 187.5 lbs retail gained, 250
lbs Food service gained. At 2 per week could result
in the possible gain of 18,000 lbs a year produced
on this line.
13. Idea’s
• Retractable hose reels at the formers and mixers.
• Water on / off is controlled by a lever instead of a turn
handle.
• 2 pressure washers that are on carts and water line is
hooked up and un-hooked like an air line. The formers
have this connection? Could be a spray hose connected
to the former line.
• 10-30-07 Rinse and plate change done in 18.75 minutes
total gap time (goal is 15 min). Waiting on back half
issues. On this day, saving 2.5 minutes would have
yielded 129.75 lbs by saving 2.5 minutes or 224 lbs by
meeting the 15 minute goal through time saving.
15. B ulge r W he a t M a t e r ia l $ $ V a r ia n c e by M on t h. .
$1,907. 00
$1, 384. 00
$2, 487.00
$2,612.00
$698. 00
$1, 346.00
34 30 32 31 20 27
0
500
1000
1500
2000
2500
3000
May-07 Jun-07 Jul-07 Aug-07 Sep-07 Oct-07
16. A v g. LB S . Los s pe r r un .
.
56. 09
46. 13
77.72
84. 26
34.90
49. 85
0. 00
10. 00
20. 00
30. 00
40. 00
50. 00
60. 00
70. 00
80. 00
90. 00
May-07 Jun-07 Jul-07 Aug-07 Sep-07 Oct -07
17. Raw Material Variance 50/50 Oil
Goal
Reduce Material Variance by 50%
Team Members
John King
Barbara Valentine
Dean Shirra
Edith Ganon
And Many More
10/10/07
19. Loss vs Number of Run
15 8 13 6 4 8 5 10 4 7
4503
4313
2729
5545
-183
20
-162
1034
2261
350
-1000
0
1000
2000
3000
4000
5000
6000
Jan Feb March April May June July Aug Sept Oct
# of runs
$ Overage
Had a run that the
Form was not filled
out. Had a Meeting
with Operators.
Processes is not being
followed in Sanitation and
Warehouse, talked to Cesar
and still working with Ronnell.
21. Sample/Log PAT – Tracking
SWING SHIFT - MICRO SAMPLES
94%85%
62% 80%
43%
89%
0
50
100
150
MAY JUN JUL AUG SEP OCT
Month
SamplesandLogs
TurnedinOnTime
(%)
Logs
Samples
GOAL: 100%
DAY SHIFT - MICRO SAMPLES
94%95% 89%
72%
0
50
100
150
MAY JUN JUL AUG SEP OCT
Month
SamplesandLogs
TurnedinOnTime
(%)
Logs
Samples
GOAL: 100%
22. Process Sanitation PAT - Tracking
CN PRODUCT RETESTS (2007)
60%
100%
0%
none 0%
83%
50%
100%
100%
0
20
40
60
80
100
120
08/06-
02/07
MAR APR MAY-
SEP
OCT
Month
NoRetestNeeded(%)
Hamburger
Tenders
GOAL: 100%
Pre-op Swabs
93% 92%
96% 96%
94%
95%
89%
85
90
95
100
APR MAY JUN JUL AUG SEP OCT
Month
%Passing
GOAL: 90%
Drains - Environmental Swabs
0/1
10/10
7/10 3/5
6/6 2/2
8/10
1/5
1/1
nonenone nonenonenone
0
50
100
150
AP
RIL
M
AY
JU
N
JU
L
AU
G
SE
P
O
C
T
Month
%Passing
Series1
Series2
GOAL: 90%
23. Temp Training for Temp
Agencies PAT
Team Members:
Nick Wadsworth
Jennifer Hummel
David Blackner
Barbara Valentine
Ronnell Porter
Cesar Pajuelo
Dean Shirra
24. Complete - Tracking
• Implemented: Mon. 8-27-07
• Will have a follow-up meeting on 11-29-07
• Waiting on turnover metrics from Strategic
• GMP videos to be ran in the break rm./team rm.
GMP NOTICES
36 34
24 25
16
25 22
159 11 6
0
20
40
M
AR
APR
M
AY
JU
N
JU
L
AU
G
SEP
O
C
T
Month
#ofGMPNotices
Given
Total
Temps
GOAL: 10 total; 5
temps
25. Mentoring Program PAT
Team Members:
Nick Wadsworth
Jennifer Hummel
David Blackner
Barbara Valentine
Ronnell Porter
Cesar Pajuelo
Dean Shirra
John King
Kurt Geiger
26. PAT Goal:
To create better skilled/qualified future and
current permanent floor employees, so
that they are more aligned with our current
business model.
27. Problems with Old Mentor Program
• No time frame for the mentoring
relationship caused the mentors to rush
through the training
• Unqualified mentors were selected
• Lack of supervisor buy-in
• Incomplete mentor training
• In complete mentee training
28. Criteria for Mentor Selection
1. need to have the necessary knowledge, skills,
abilities (know how all departments function, know
who the key players are)
2. adhere to company policy: attendance, safety, etc.
3. respected by co-workers
4. team player: has been involved with continuous
improvement teams or is interested in becoming
involved
5. able to practice confidentiality with co-workers
6. overall happy about/committed to their job
29. Last Meeting: 11-1-07
• Finished the design phase of the “Mentor Training”
portion of the project
• # of mentor in pilot program: production (1); quality (1);
sanitation (1); warehouse (2); maintenance (2)
• Mentor training:
– Leadership training including an exercise (done by HR)
– training booklet – GMP’s, safety, 5S/lean/kanban, continuous
improvement (done by safety/quality/mentor PAT member)
• Total of 2 to 4 trainers
• 3-5 hours of training done on Fridays
• Must pass a quiz with 85% or higher
• Management meets with mentors one-on-one before and
after training
30. Next Meeting: 11-15-07
• Design phase of “Actual Mentoring”
portion of the project
– This has been started
– Process breakdown/brainstorming
31. Action Plan
Task Responsibility Est. Comp Date
Discuss and decide on framework for
the “Mentor Training” portion
Team DONE
Discuss and decide on framework for
“Actual Mentoring” portion
Team 11-29-07
Design mentor training & quiz Sub-team assignments Dec/Jan, TBD
Design training booklet & quiz Sub-team assignments Dec/Jan, TBD
Write the SOP Sub-team assignments Dec/Jan, TBD
Select mentors Team January, TBD
Brief all supervisors/mgrs. Sub-team assignment January, TBD
Train the first mentors HR/Operations/QA January, TBD
Choose first mentee(s) Team January, TBD
