final presentation-2-23-12

“One Team – No Borders”

Krones Starmatic Labeler

Salad Dressing Line

Downtime Reduction

“One Team – No Borders” IntroductionCharter• Problem Statement - During the first 8 periods of 2011 the Starmatic

Labeler saw 10,285 minutes of downtime and accounted for 30.7% of the total unplanned equipment downtime for the Liquid Salad Dressing Line. The reliability of this piece of equipment was responsible for stopping the filler operation 2,842 times, thus interrupting the production process. At an average rate of 160 bottles per minute, this downtime accounts for lost production of 205,702 bottles per period.

• Project Objective – Decrease the Starmatic Labeler unplanned downtime by at least 50% or 643 minutes per period by March 1, 2012. This will be accomplished by optimizing the Maintenance Excellence process to ensure greater reliability and consistency across all three shifts. This project will deliver an estimated annual cost savings of $58,008 and set a Maintenance Excellence standard that can be applied across the plant.

“One Team – No Borders” Team

“One Team – No Borders”Identifying areas for

Improvement

FMEA

Process Map

Fishbone

“One Team – No Borders” Focus Areas

• Preventative Maintenance• Cleaning and Inspection• Training / Troubleshooting• Equipment Repairs• Changeover• Material - Labels

“One Team – No Borders”

PREVENTATIVE MAINTENANCE

Want to move from Reactive to Proactive Operations

“One Team – No Borders” LubricationProviding a detailed PM procedure for greasing the equipment

Daily Gripper cylinder: 1 drop

per cam roller station (4) after each caustic

Lubricate pallet turret, one drop per: bushings (5 front; 6 back) on pallets

Lubricate the glue roller upper/lower bearing

“One Team – No Borders” LubricationWeekly Lubricate remote grease

fittings and check the reservoir for the bottle plate

Lubricate the pusher-plate guide rod on the label baskets so the pusher plate travels smoothly and freely

Oil the rollers on the cam followers

Lubricate the three gearwheels underneath the panel with a light coating of grease

“One Team – No Borders” Inspection

Frequency of Inspection Monthly vs Quarterly

Procedures Better detailed equipment checks

Change Over Parts Inspecting parts

Planned Job Package Repetitive File 50,000 in EMPAC Retiming equipment

“One Team – No Borders” InspectionWeekly Visual Inspection

“One Team – No Borders” Inventory

ObsoleteSurplusLocation

Standardization

“One Team – No Borders” Cleaning as Inspection

Before After

“One Team – No Borders” Cleaning Procedures

“One Team – No Borders”Daily Operator Inspection

• Operator Ownership

• Ensures Daily Inspection Are Completed

• Identifies Maintenance Issues

“One Team – No Borders”Operator Training

• Krones Training• Developing Customized Training Manual

– Knowledge Assessments• Troubleshooting Guide

“One Team – No Borders” Maintenance Training

Part of the charter was to improve the efficiency of our mechanics on

identifying breakdowns and the ability to correct issues quickly with consistency. This will help eliminate extended down time

events and create common adjustment points.

“One Team – No Borders” Maintenance Training

Training Program  66 Schedule Krones to Conduct General Equipment training for Operators

and Mechanics 

67 Schedule Operators and Mechanics to attend Training (provide necessary coverage)

68 Document Standardized Work Procedures and SOPs for running equipment

69 Develop operator training plan with certification requirements for future operators and mechanics

70 Create Troubleshooting Gide  71 Develop daily operator checklist  

Developed an action register to determine opportunities for Maintenance Training

“One Team – No Borders” Maintenance Training

• Krones Training:– Doug Paswatters– January 3rd thru 6th of 2012

Presented Cold-Glue Rotary Training for Line Technicians and Maintenance

“One Team – No Borders” Changeovers

• Reviewed the current change over procedures and updated them to a step by step system to achieve more consistent results. With this new format we are looking to have repeatable change overs that deliver consistency, quality and reduced time on vertical start up’s.

“One Team – No Borders” Changeovers

91 Make a detailed list of all adjustments and settings that can be made to the labeler

92 Verify set points for each adjustment and each package size93 Document changeover procedures with SOPs94 Conduct changeover training with Operators and Mechanics95 Mark all gages and scales with min/max settings96 Review current changover procedure97 Develop Changeover Checklist for Maintenance and Operations

Change Over Action Register

“One Team – No Borders” Changeovers

“One Team – No Borders” ChangeoversStarmatic Labeler Changeover Sequence

[ ] Back Side of Labeler Remove: Infeed Guide (adjustment) Remove: Discharge guide (adjustment)1 [ ] Remove: Discharge starwheel2 [ ] Remove: Centerguide3 [ ] Remove: Infeed starwheel4 [ ] Remove: Feedscrew5 [ ] Install: Feedscrew, and adjust to package" Remove: Bottle gate (adjustment)6 [ ] Install: Infeed starwheel Install: Infeed guide - (adjust)7 [ ] Install: Centerguide8 [ ] Install: Discharge starwheel9 [ ] Install: "Discharge guide, as required"

Front Aggregate

10 [ ] Remove: Front Label basket *The Operator should have this done before the Mechanics are finished with the Back Side of the Labeler. (Do not lift using pusher-plate rails)

11 [ ] Remove: Front Label pallets *The Operator should have this done before the Mechanics are finished with the Back Side of the Labeler.

12 [ ] Install: Label basket (do not lift using pusher-plate rails.)13 [ ] Remove: Front Gripper cylinder14 [ ] Install: Front Gripper cylinder15 [ ] Install: Front Label pallets

Back Aggregate

16 [ ] Remove: Back Label basket *The Operator should have this done before the Mechanics are finished with the Back Side of the Labeler. (Do not lift using pusher-plate rails)

17 [ ] Remove: Back Label pallets *The Operator should have this done before the Mechanics are finished with the Back Side of the Labeler.

“One Team – No Borders” Equipment Repairs

“One Team – No Borders” Equipment Repairs

Lack of proper cleaning and PM’s lead to a labeler that was unreliable, unpredictable and in need of immediate attention.

“One Team – No Borders” Equipment Repairs

• Team identified repair opportunities and formed action register.

Train oilers and supervisors on new lubrication scheduleRun water lineCam Rollers are Worn and need to be replacedReplace all sight glasses on labelerReplace all oil reservoirs on lablerReplace all gages on labelerReplace rubber seals on all of the doors

Clean / Replace all door frames

Infeed star - center hub is cracked, make sure we have a spareSmall lexan panel by the back label did not get replaced during cleaning - replace small lexan panelCheck drive belt tension so that it can be added to the PMUpdate PMs with information from cleaning day, past history and FMEAInstall quick release handles for removing brushes for cleaningResearch and develop plan for replacing/ rebuilding main gear boxInsvestigate scheduing PMs on hours vs. days

“One Team – No Borders” Equipment Repairs

• As part of the action register and PM review we replaced over 60 different worn parts

“One Team – No Borders” Equipment Repairs

• Some parts that were replacedOut with the old In with the new

“One Team – No Borders” Future Work

We will change the culture to create a

cleaner, well maintained and efficient running

Labeler

“One Team – No Borders” Future WorkImproved Lubrication Program

“One Team – No Borders” Future WorkNew established cleaning procedures

“One Team – No Borders” Future Work

Improved PM Procedures

“One Team – No Borders” Future Work

Through Training and Team Work

“One Team – No Borders” Label Check Sheet

Kroger State Ave - Labeler Check Sheet Operator:____________________________Date:_______________________________

Time Product Name Front Label Back Label Neck Band Cap Type

Align Adhes Resource# Align Adhes Resource# Align Adhes Resource# Blue Red

1 Pre-Op2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

The first check is now considered the pre-op check. Once the labels are applied and in specifications and code dater blue and red have been set and the correct caps are in useperform the first quality check, While performing this check the line must be down when the containers meet the specifications then continue running production. It is important when checking the code dates to make sure both code daters are set correctly and are printing in the correct location on the container.

Every half hour and each changeover, check 3 containers for label alignment and proper adhesion of each label. If each label is acceptable, write "YES" in the blank provided. If not, write "NO" and note what was done to correct it in the comments section. Check the cap type against the pack specs. (Color/lined vs. unlined, etc) IF THE RESORCE NUMBER SPEC AND THE RESOURCE NUMBER USED DO NOT MATCHOR LABELS CANNOT BE APPLIED PROPERLY, SHUT THE LINE DOWN AND CONTACT A SUPERVISOR. Alignment should be no more than 1/4 inch skewed.

___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Revised 2/09/12 JB

Date Coder

• Operator Accountability

• Operator Awareness

• Eliminates Failure of Process Improvement

“One Team – No Borders” LabelsSpring Dot was here on January 24 and brought in their operators and upper management as well as one of their owners for this meeting. We used samples during the meeting as examples of improper cuts.

Spring Dot response:

We can just make the switch as soon as you can purchase the correct paper and obsolete the old inventory.

“One Team – No Borders” Downtime Tracking

“One Team – No Borders” Control Plan

Sustained Improvement Requires….• Involvement and Attention from Everyone!

– Operators, Mechanics, Production and Maintenance Supervisors, Superintendent, Maintenance Manager, Maintenance Engineer, QA, Kaizen Team, HR….

** Control Plan will be reviewed with all necessary parties for approval and signatures

“One Team – No Borders” Results

Minutes of Starmatic Labeler Downtime by Period

“One Team – No Borders”Minutes of Downtime Per Shift

(12/8/11 - Present)

12/8/2011

12/13/2011

12/16/2011

12/21/2011

1/6/2012

1/11/2012

1/17/2012

1/20/2

012

1/23/2

012

1/26/2012

1/29/2012

2/1/2012

2/4/2012

2/7/2012

2/10/2

012

2/13/2

012

2/16/2012

0.0

20.0

40.0

60.0

80.0

100.0

120.0

1st Shift Minutes Down

12/8/2011

12/13/2011

12/16/2011

12/21/2011

1/6/2012

1/11/2

012

1/17/2

012

1/21/2012

1/24/2012

1/27/2

012

1/30/2

012

2/2/2012

2/6/2012

2/9/2012

2/12/2012

2/15/2012

0.0

20.0

40.0

60.0

80.0

100.0

120.0

2nd Shift Minutes Down

12/8/2011

12/13/2011

12/16/2011

12/21/2011

1/10/2

012

1/13/2

012

1/20/2

012

1/23/2

012

1/26/2

012

1/29/2

012

2/1/2012

2/4/2012

2/8/2012

2/11/2

012

2/14/2

012

2/17/2

0120

20

40

60

80

100

120

3rd Shift Minutes Down

Minutes Down Per Shift Baseline (1/30/11 – 12/6/11) Trend

“One Team – No Borders” Downtime Trend

Reduced Variation

“One Team – No Borders” ResultsBaseline

#1 Downtime Event = Labeler30.7% of Downtime caused by Labeler After Improvements

#1 Downtime Event = Changeover24.2% of Downtime caused by Changeover

17.8% of Downtime caused by Labeler

“One Team – No Borders” Improvement and Savings

Avg. DT Min /Shift

Baseline (1/30/11 – 12/6/11)

After Improvements (12/7/11 - Present)

50% Reduction Goal

% Improvement

1st 10.4 10.8 10.0 ------

2nd 29.5 15.8 10.0 46%

3rd 20.2 15.2 10.0 25%

Total 60.1 41.8 30.0 30%

** In the 7 shifts since the maintenance/rebuild on 2/18-2/19 we have averaged 3.98 minutes of downtime per shift! That’s an 80% improvement from the baseline average.

“One Team – No Borders” Projected Savings

Actual Savings

12 13 1 2 3 4 5 6 7 8 9 10 11$0.00

$20,000.00

$40,000.00

$60,000.00

$80,000.00

$100,000.00

Project Savings - Calculated from Unplanned Downtime % Improvement** Savings calculated from average period downtime reduction only

30% Projected Improvement 50% Projected Improvement 75% Projected Improvement 90% Projected Improvement

“One Team – No Borders” What’s Next?30% Improvement = Current State

50% Improvement = Expectation after 2/18-2/19 Weekend Repairs

75% Improvement = Projected improvement after completion of the following: • Customized Operator Training Manual, Troubleshooting and Training• Improved Springdot Label Quality• Neck Band Labels with Horizontal Grain (3/17)• Downtime Code Standardization

90 % Improvement = Recommendations for future Teams/Kaizen Events• Rapid Changeover Event • Customized Maintenance Training Manual and Training Program• Cleaning Cabinet

** Control Plan Must Be Followed to Sustain Improvements

“One Team – No Borders”

Questions?