site overview & 5 s
DESCRIPTION
Overview of plant and an update on 5S progressTRANSCRIPT
- 1. Welcome to LITTLEBOROUGH Site Overview 5S
2. Littleborough Location LITTLEBOROUGH HADDENHAM 3. Factory Plan View Whitelees Rd Freehold land New Mill St Stockton St 4. 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
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- + seasonal requirements
- Total Site area of 6000 m 2
- New Mill Street Factory Footprint of 4000 m 2
- New Mill Street site predominantlyproduces Dip Pots, Sachets and flexiblepacks (pouches, bag-in-box).
- 24/5 shift pattern (24/6 during high demandperiods)
- 90 Operations employees
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- + seasonal requirements
5. 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
6. SKU Count Tonnage1200T/wk Finished Goods SKUs 330 Packaging formats 35 Ingredient SKUs 320 Packaging SKUs 550 7. 5S At Littleborough 8.
- 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 9.
- Project Brief
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- Build a 5s Workshop
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- Improve the Working Environment
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- Facilitate in Organising Work Areas
- Used an Existing Workshop Presentation
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- Presentation Used by Nigel in the Past
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- Presentation Branded to a McCormick Style by Facilitator
Starting Point 10.
- 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 11.
- Pre-Training Information Booklet for Attendees Written & Produced In House
Before The Workshop 12.
- Introduction / Overview of 5s
- 1 st5s Audit
- Create A Vision
- SORT
- SET
- SHINE
- STANDARDISE
- SUSTAIN
The Workshop 13.
- 1 stAudit
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- Carry Out a Detailed Audit of The Area
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- Complete a 5s Audit Sheet
- Create A Vision
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- Categorise The Possible Improvements To Be Made
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- Current Conditions / Desired Conditions
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- Making Operations Easier
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- Action Plan
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- Safety
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- Quality
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- Equipment Maintenance
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- Efficiency Of Work
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- Inventory Levels
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- Information Sharing
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The Workshop 14.
- Sort
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- Red Tag Technique
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- Clear Area
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- Red Tag Area
- Engineers Red Tag Area - WLR
The Workshop 15.
- BEFORE SORT
- AFTER SORT
- NMS Dry Prep
The Workshop 16.
- SET
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- Organise Area To Suit
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- 30 Second Rule
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- Mark & Label Areas
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- Equipment
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- Storage
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- WIP
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- Inventory
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The Workshop 17.
- SHINE
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- Inspection
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- Early Detection
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- Create Shine Standard
The Workshop 18.
- STANDARDISE
- SUSTAIN
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- Overview of the final 2s
The Workshop 19. The Workshop Each Certificate Personal to Recipient, Individually Signed & Copy Displayed 20.
- Audits
- Newsletters
- 5s Ideas
- Action Plans
Post Workshop 21.
- Audits Carried Out By Trained Audit Team
Post Workshop 22. Post Workshop 23. Post Workshop Comments 24.
- Complete Standardise & Sustain Training
- Planned Move of Equipment Area 5S
Next Steps 25. Equipment Moves 26.
- Set a Budget for 5S Improvements
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- Re-Organisation of Work Areas
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- Improvement Ideas
- Complete Engineering Areas 1 st
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- If Engineers Buy In Improvements Will Be Easier To Drive
- Plan Final 2S Sessions
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- Commit to Completing The Workshop
What Would We Do Better? 27.
- Awards & Recognition
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- Best Audit Score
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- Most Improved
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- Stuck In The Mud
What Would We Do Better? 28.
- Commit Resources and Plan
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- All Shifts On The Workshop
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- Planned Areas To Be Shutdown
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- Involvement From All Levels
- Own Facilitator
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- Ownership of 5S Philosophy
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- Consistent Approach
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- Understanding Of Site
What Did We Do Right? 29.
- Engineers On Every Workshop
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- Break Down Barriers
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- Able To Repair Problems Immediately
- Momentum
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- Complete Areas In Quick Succession
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- Concentrate On The 1 st3S
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- Stops Stagnation
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- Everyone Can See The Commitment
What Did We Do Right? 30. Visual Management Planning The Workshops 31. Visual Management Branding The 5S Philosophy 32. Visual Management Branding The 5S Philosophy 33.
- Quantity Control
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- Control of Stock Levels
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- Reminder to Re-Stock
Visual Management 34.
- Use of Shadow Boards
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- Controls Equipment
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- Missing Equipment Identified
Visual Management 35. Improvements 36.
- Rolled Out 5S in our South African Dry Plant (Midrand)
- Blue Room
- Rainbow Room
South Africa 37.
- Engineering Area One Of The 1 stTo Embrace 5S
South Africa 38. South Africa 39.
- Within 3 Months All Dry Plant Employees Completed a 5S Workshop
- Interest From Other Sites In The U.S.A., Turkey & China
South Africa 40. FACTORY TOUR