supply chain live superior service, deliver sustainable, profitable growth sep 2013 larry gibson –...

SUPPLY CHAIN

LIVE SUPERIOR SERVICE,DELIVER SUSTAINABLE,PROFITABLE GROWTH

SEP 2013

Larry Gibson – Manufacturing Director

COVINGTON

FACTORY TIMELINE

Slim Fast Company acquired by Unilever

High strength waste treatment facility completed

1st Super-shots line in North America installed and operational

Project Yorktown (Slim-Fast Restructuring)

Project Lexington (Super Shots Exit)

00

03

Project Odyssey (Ice Cream). Engineering starts.

Slim Fast RTD production ceases (June 30th)

Ice Cream Manufacturing begins in Space Saver (PIC) on Aug 29th

1st Stickless extruded Line (Klondike) starts on Oct 26th with Reese’s

Moulded Line starts on Dec 15th with Mighty Minis production

07

09

10

11

Land O’ lakes (copacker of Slim-Fast ) completes construction and inititates start-up. Building size is approx. 400,000 sq. ft.

Slim-Fast Foods Company assumes ownership of Covington

R&D Pilot Plant Start-up

280,000 sq. ft. expansion (Distribution Center)

Two additional packaging lines installed (doubling capacity).

Processing & canning expanded by 50%

96

98

99

00

1996 - 2000 2000 - 2009 2010 - 2011


THE JOURNEY TO ICE CREAM

Infant

Toddler

Adult

Child

Teen

We are here


Factory Passport

Building Area: 808,000 sq ft (75,000 sq mt)

Land Area: 3,556,000 sq ft (330,000 sq mt)

PIC - Packaged Ice Cream(Breyers)

Stickless Extruded(Klondike)

Molded(Popsicle / Good

Humor)

2013 Volumes: 95,016 Liton

PIC: 54,991 Liton (51 SKU’s)

Klondike: 21,655 Liton (4 SKU’s)

Molded: 18,370 Liton (12 SKU’s)

Production Lines: 14 (pack capacity 206,000)

- SS-1: PIC - speed 70cpm - SS-2: PIC - speed 70cpm - SS-3: PIC - speed 70cpm - SS-4: PIC – speed 70cpm - KL-1: Klondike (stickless extruded) – speed

600bpm - KL-2: Klondike (stickless extruded) – speed

600bpm - KL-3: Klondike (stickless extruded) – speed

600bpm - Gram 1: Molded – speed 140 pcs/min - Gram 2: Molded – speed 455 pcs/min - Gram 3: Molded – speed 455 pcs/min - Gram 4: Molded – speed 280 pcs/min - Gram 5: Molded – speed 624pcs/min - Gram 6: Molded – speed 520 pcs/min - Gram 7: Molded – speed 624 pcs/min Mix Room: 2- PIC Mix Room capacity: 6,000gph* (2

HTST*)- Novelty Mix Room capacity: 6,000gph* (2

HTST)Refrigeration:- Current Refrigeration Load: 5,875 ton- Current Ammonia Load: 125,000 lbsCold Storage:- Fully Automated – 4,000 pallet positions

2013 Budget: €63.7M at $1,2831: €1.00

STAFFING (Jan/13)13 Managers

22 Supervisors (WL1)462 Hourly Employees

178 Temporary Workforce


OVERVIEW

What does a modern foods factory look like?AutomationRoboticsHMIWhat does this mean for operators?Math/Analytical Skill/Reading comprehensionWhat Unilever is doing to continuously improve our workforce!OJTBLITZIRT for All (Unilever University)Advanced Training


TEAM WORK


GRAM

Consumer Safety, Teammate Safety & Quality

Operators Performing a Changeover

Gram Equipment

Robotic packaging

Automated Case packing


SPACE SAVER


Graphical Equipment representation

Breyers Modern packaging equipment

Computer Touch Screen Online statistical controls

Automated

Downtime analysis


KLONDIKE


Delicious products!

Klondike Robots

Modern Quality assurance equipment

High volume production

Ice Cream Production


MIX


In department Mixing Calculations

Batching

High Tech HTST

SUPPLY CHAIN


B ASICL EARNINGI NTENSIVET RAINING Z ONE

TRAINING GUIDESUNILEVER COVINGTON, TN


COMPETENCY CHECK GUIDEUSED TO VALIDATE OPERATOR IS FULLY

COMPETENT TO RUN THE TECHNICAL ASPECTS OF THE EQUIPMENT.

Training Manualused to guide Operator through all

technical aspects of their daily functions.


SKILLS TRAINING MATRIX

Klondike

Warehouse

Space Saver

Mix


BUT ALL THIS IS NOTENOUGH!


COVINGTON PEOPLE DEVELOPMENT

Mission:Enable factory workers to learn and grow their contributions and rewards by building skills that allow them to meet our consumer and company needs

Deliverables:•Skilled/ Flexible workforce•Highly Engaged workforce•Environment where “Variable Pay” is the •Motivation

Competitive Advantage:•Technical Business partners are running the business day to day. •Employees are the investment and deliver stakeholder returns.•The Vision of the Site and Company is internalized and demonstrated

PIPELINEIndustrial Readiness

Training

NEW HIREJob Specific Training

(BLITZ)

TEAM SKILLSTPM/WCM

Team working

REMEDIAL CORE SKILLS

Operator & Maintenance Skills -

SMT

TECHNICAL SKILL ADVANCEMENTTechnical Skills –

SWTCCUNILEVER U.

Prospective

Candidates

• Soft Skills• Teamwork• Math• Reading• Locating

Information

• OJT Train-the-Trainer

• Basic Machines

Validated Pre and Post tests• CRC• Mechanic

al Aptitude

IRT

Maintenance• Shop Math• Operator Core• Fundamentals• Pneumatics &

Hydraulics• Electrical

Components• Pump Basics• Valve Operation• Failure Analysis• Gearbox & Bearing• Advanced

Pneumatic• Advanced

Hydraulic• Advanced

Electrical• Pump Maintenance• Intro to Welding• Machine Shop

Practices• Machine

Adjustments• Ladder Logic• PLC Advanced

Electrical

Operator• Blueprint

Reading• Measurement• Hand Tools• Mechanical

Components I• Bearings &

Lubrication• Mechanical

Components II• Machine

Adjustment

MECHANICAL• Workplace Safety• Preventive

Maintenance• Quality Control & SPC• Hydraulic/Pneumatic• Fluid Power

Distribution• Piping and Pneumatic• Mechanical

Installation• Basic Pneumatic

Controls• Basic Hydraulic

Controls• Intermediate

Pneumatic• Intermediate

Hydraulic• Power Transmission

Systems• Advanced Mechanical

MAINTENANCE PROGRESSION

Electrical

MechAniaL

Electrical

ConTrols

OR

Maintenance Technician I Skill Assessment Test

Maintenance Technician II Skill Assessment Test

Maintenance Technician III Skill Assessment Test

AAS Degree

AdvancedIndustrialIntegratedTechnology

CertificatePrograms

Certificate

Programs

Apprenticeship Program

ELECTRICAL

• Workplace Safety• Preventive

Maintenance• Quality Control &

SPC• Basic Electricity• Power Development• Electrical Power

Distribution• Electrical

Installation• Basic Electrical

Controls• Intermediate

Electrical Controls

CONTROLS• Workplace Safety• Preventive

Maintenance• Quality Control &

SPC• Principles of

Instrumentation• Integrated

Process Control• Integrated

Process Management

• Programmable Logic Controls

Controls

ConTrols

Mechanical

MechAniaL

CORE


SO WE LEVERAGE OUR PARTNERSHIP WITH SOUTHWEST!

UNILEVER UNIVERSITY SPONSORED BY

SOUTHWEST TENNESSEE COMMUNITY

COLLEGE

supply chain live superior service, deliver sustainable, profitable growth sep 2013 larry gibson –...

Documents

molded speed

pic speed

pic speed

pcsmin gram

bpm gram

liton pic

profitable growth overview

skus klondike