1. Prepare AM vision, mission statement and objectives.
2. Prepare AM slogan. 3. Develop autonomous maintenance implementation plan showing machine classification and timing for the AM steps up to end of 2015. 4. Identify AM pilot machine from machine classification. 5. Set pillar targets for three years for both pillar & pilot machine to include: - Number of defect tags per employee per week - Number of Before/After improvements - Number of One Point Lessons - Machine cleaning time KAI TARGETS (Direct - AM training time targets) - Volume per shift - OEE - Number of Breakdowns per shift - Number of minor stops per shift KPI TARGETS - % Defect and rework (Indirect targets) - Number of safety incidents per year 6. Select another project (to be solved by using 10-step kaizen) of excessive leakage or usage of consumption material 7. Prepare AM board layout. 8. Complete the AM pillar membership to be multifunctional
Planned Maintenance (Ram Kumar):
1. Prepare PM vision, mission statement and objectives.
2. Set pillar targets for three years to include: - Number of unexpected stops greater than 10 minutes - % operation time lost - MTBF - MTTR - Lubricant consumption per ton of Pasta - Spare parts inventory level - Energy consumption / ton of output - Maintenance Spending in Naira per tonnage of output - TPM Savings 3. Develop PM Master Implementation plan. 4. Complete the PM pillar membership to be multifunctional 5. Prepare A5 size failure analysis form ASAP 6. Select a Zero failure pilot project 7. Select a focused area energy saving project 8. Commence the recording of breakdowns with form and start immediate why why analysis on breakdowns. Develop improvement action plan 9. Give emphasis to support AM tag resolving activities 10.Subdivide plant to number of fitters and give numerical personal targets to achieve for each area
Focused Improvement (Alimi Olumide):
1. Prepare FI vision, mission statement and objectives
2. Set pillar targets for three years 3. Develop FI master implementation plan 4. Categorize the site losses using the 16 major losses as guide 5. Complete a sample OEE calculation with the standardized losses for at least two packing machines 6. Select pilot SMED project for product change over in Pasta line 7. Select Decreasing wrapper change time project 8. Obtain correct expense costing from accounts for one machine for a year and bring correct measurement of OEE losses for same machine for the same period. Get them ready for cost loss analysis workshop 9. Develop a table to show products versus production lines containing ideal cycle times 10.Develop another table to show the volume to be produced per month per product 11.From 9) and 10) derive a table which shows production line saturations (the theoretical time calculated should be corrected by OEE) 12.Complete the FI pillar membership to be multifunctional
Quality Maintenance (Ada Amogu):
1. Prepare QM vision, mission statement and objectives
2. Set pillar targets for three years 3. Develop QM Master Implementation plan 4. Start capturing and properly recording all process and packing defects and rework 5. Start capturing and properly recording consumer complaints 6. Develop a defect policy deployment for Pasta 7. Develop a quality improvement roadmap from the above 8. Start organizing daily quality meetings with production and maintenance personnel on the shop floor 9. Launch a pilot figure 8 defect reduction project 10.Do a material balance analysis of Pasta operation 11.Complete the QM pillar membership to be multifunctional
Safety, Health and Environment (Peter Odion):
1. Prepare SHE vision, mission statement and objectives
2. Set pillar targets for three years 3. Develop SHE master implementation plan 4. Review site risk assessment 5. Develop negative map by using red dots in order to show all kinds of accidents and risks for the last five years. 6. Select a pilot project area where red dots are most intensive. 7. Plan to take all different types of proactive actions. 8. Map and measure waste generation I a) absolute amount and b) per ton of product sold 9. Complete the SHE pillar membership to be multifunctional
Early Management (Andrea Girolimetto):
1. Prepare EM vision, mission statement and objectives 2. Using the given training module, develop Golden Pasta early management process flow showing details of all the stages 3. Customize the given early management problem list and fill for the Pasta plant 4. Develop a Maintenance Prevention-MP form 5. Complete the EM pillar membership to be multifunctional
TPM in Administration (Joseph Adebambo):
1. Prepare pillar vision, mission statement and objectives
2. Set pillar targets for three years 3. Develop pillar master implementation plan 4. Prepare list of all offices including production offices 5. Arrange an office cleaning exercise on a weekend(or public holiday) using set rules and standards 6. Select a pilot office for improvement 7. Prepare a tag for office anomalies 8. Make a site layout to show all stocks and showing stock type, weight, stock days and Naira value
Training and Development (Sam Obukelihor):
1. Prepare pillar vision, mission statement and objectives
2. Set pillar targets for three years 3. Develop pillar master implementation plan 4. Develop an operator skill profile and conduct a skills gap analysis of one operator, and hence determine the detail training topics.
General (Kingsley):
1. Set TPM targets (PQCDSMEI) for three years for Pasta and split to pillars. Pillars to use given targets to develop own targets for same period