Initative Activity

W k1

W k2
B o ttl i n g l i n e l a b o IuMr P R O V E O V E R A L L P R O D U C T I O N L I N E O E E F R O M 4 W E E K L Y E X I T L E V E L F O R 2 0 1 0
SI Intiative Activities
P ro je c t # 0 Owner Owner

Brief Senior Team and highlight targets and activities on the

Brief the factory CI Plan
teams of the Set the vision for the factory regarding the improvement and
Improvement generate understanding and focus.
Brief Shift Managers, Supervisors and Lines teams
objectives for 2011

F 5 = 3 9 .0 8 % ) T O 4 W E E K L Y E X IT L E V E L F O R 2 0 1 1 O F 5 0 %
highlighting their involvement in the process, the targets and
activities.

Current 16wk average OEE is 38.84%, the "Best of the best"

Implement the 4 stage OEE improvement methodology
OEE achieved during this period has been 56.42%. To
across each shift and line. Teams to be briefed in the
Line A achieve this requires a 14% reduction in the average weekly
methodology and utilise exsisting "S.I.C" sheets to support
downtime from 1211 mins to 1045mins with an average BPM
the process.
of 81

Current 16wk average OEE is 43.36%, the "Best of the best"

OEE achieved during this period has been 50.07%. To Simplify the existing OEE dashboard data and provide an
Line B achieve this requires a 2% reduction in the average weekly easy method for identifying line OEE performance and focus
downtime from 1038 mins to 1024mins with an average BPM improvement activities.
of 50.

Current 16wk average OEE is 28.40%, the "Best of the best"

Implement "SMED/Quick Change over" methodology to
OEE achieved during this period has been 48.25%. To
P ro je c t # 1

implement a standardised/best practice approach in

Line C achieve this requires a 27% reduction in the average weekly
reducing current changeovers. (Utilise the "Very Basic
downtime from 589 mins to 428mins with an average BPM of
Process For Reducing Changeovers")
67

Current 16wk average OEE is 41.63%, the "Best of the best"

Drive equipment reliability improvements through the
OEE achieved during this period has been 50.27%. To
utilisation of line data. Brief the production line "Senior
Line D achieve this requires a 58% reduction in the average weekly
Operatives" to ensure all downtime is recorded under the
downtime from 975mins to 406mins with an average BPM of
appropriate category on the line "SIC" sheets.
82

Current 16wk average OEE is 36.54%, the "Best of the best"

OEE achieved during this period has been 48.01%. To Formalise a regular product/line run rate review between
Line 1 achieve this requires a 23% reduction in the average weekly operations & planning as part of a line performance
downtime from 2111mins to 1615mins with an average BPM improvement initiative.
of 50

Current 16wk average OEE is 44.59%, the "Best of the best"

OEE achieved during this period has been 58.43%. To
Line 2 achieve this requires a 25% reduction in the overall average
weekly downtime from 1845mins to 1377mins with an
average BPM of 45
p r o d u c ti v i ty i m p r o v e m e n t
Evaluate current Planned Preventative Maintenance activities
and establish their effectiveness in reducing equipment
related downtime.

To achieve an average overall OEE of 50% Devise a generic daily shift handover report to collate and
Overall through a targeted reduction in the overall communicate all issues affecting factory 2 & 5 performance
downtime by 25%, and costs.
P ro je c t # 2

Factory 2
Undertake a labour mapping exercise within each factory to
Review the current labour deployement within the factoy and
establisd the current baseline. Utilising this data identify,
identify opportunities to improve productivity whilst
challenge and implement effective productivity improvement
maintaining bothe product quality and production efficiency.
opportunities.
Factory 5

Using the current data collection system, formalise a

During the first 13 weeks of 2011 the average yield variance
"Checking Methodology" for Orange, Lime & Lemon yields
experienced has been 42.89% compared to the budget
Orange Yield to identify and report losses at each stage of the process
C i tr u s & P u r e e Y i e l d i m p r o v e m e n t

target of 45.1%. This equates to an average weekly loss of

and validate the existing losses being used as part of the
approx £4.85k or an annualised loss of £252k
acceptable yield Loss.

During the first 13 weeks of 2011 the average yield variance Review the current loss process flow and identify any
experienced has been 32.2% compared to the budget target additional/missed routes not currently being recorded.
Lime Yield
of 39.5%. This equates to an average weekly loss of approx
P ro je c t # 3

£1.43k or an annualised loss of £74.3k

Record and action the initial fruit yield evaluation practice
(reference machine) and track yeilds daily/weekly.
During the first 13 weeks of 2011 the average yield variance
experienced has been 35.78% compared to the budget
Lemon Yield
target of 37.9%. This equates to an average weekly loss of
Review the current practice of short squeezing runs (limes)
approx £1.95k or an annualised loss of £78k
and identify an alternative approach to reduce current yield
losses.

Review the operational effectivness of the "Pigging System"

and establish an effectiveness measure to ensure optimum
return on the system.
During the first 13 weeks of 2011 the average yield variance
experienced across key purees has been approx 10% lower
Puree Yield
than budgeted target This equates to an average weekly
Design a suitable data analysis system for "Blending"
loss of approx £1.5k or an annualised loss of £76k
losses and provide weekly feeback on losses.

Implement the 4 stage "Blending Yield" process

improvement methodology with the night shift teams.
 p ro d u c tiv ity F O R 2 0 1 0 O F (F 2 = 4 0 .6 8 % , F 5 = 3 9 .0 8 % ) T O 4 W E E K L Y E X IT L E V E L F
Initative Week 20 Week 21

B o ttlin g lin e la b o u r IM P R O V E O V E R A L L P R O D U C T IO N L IN E O E E F R O M 4 W E E K L Y E
SI Intiative Baseline Target
Owner Measure Savings Measure Savings

Current 16wk average OEE is 38.84%, the "Best of the best"

OEE achieved during this period has been 56.42%. To
Line A achieve this requires a 14% reduction in the average weekly 38.84% 50%
downtime from 1211 mins to 1045mins with an average BPM
of 81

Current 16wk average OEE is 43.36%, the "Best of the best"

OEE achieved during this period has been 50.07%. To
Line B achieve this requires a 2% reduction in the average weekly 43.36% 50%
downtime from 1038 mins to 1024mins with an average BPM
of 50.

Current 16wk average OEE is 28.40%, the "Best of the best"

OEE achieved during this period has been 48.25%. To
28.40% 50%
P ro je c t # 1

Line C achieve this requires a 27% reduction in the average weekly

downtime from 589 mins to 428mins with an average BPM of
OF 50%

67

Current 16wk average OEE is 41.63%, the "Best of the best"

OEE achieved during this period has been 50.27%. To
Line D achieve this requires a 58% reduction in the average weekly 41.63% 50%
downtime from 975mins to 406mins with an average BPM of
82

Current 16wk average OEE is 36.54%, the "Best of the best"

OEE achieved during this period has been 48.01%. To
Line 1 achieve this requires a 23% reduction in the average weekly 36.54% 50%
downtime from 2111mins to 1615mins with an average BPM
of 50
Current 16wk average OEE is 44.59%, the "Best of the best"
OEE achieved during this period has been 58.43%. To
achieve this requires a 25% reduction in the overall average
Line 2 44.59% 50%
weekly downtime from 1845mins to 1377mins with an
average BPM of 45

To achieve an average overall OEE of 50% through a

Overall
targeted reduction in the overall downtime by 25%,
P ro je c t # 2

im p ro v e m e n t

Factory 2

Review the current labour deployement within the factoy and

identify opportunities to improve productivity whilst
maintaining bothe product quality and production efficiency.

Factory 5
C itru s & P u re e Y ie ld im p ro v e m e n t

During the first 13 weeks of 2011 the average yield variance

experienced has been 42.89% compared to the budget
Orange Yield
target of 45.1%. This equates to an average weekly loss of
42.9% 45.1%
approx £4.85k or an annualised loss of £252k

During the first 13 weeks of 2011 the average yield variance

P ro je c t # 3

experienced has been 32.2% compared to the budget target

Lime Yield
of 39.5%. This equates to an average weekly loss of approx
32.2% 39.5%
£1.43k or an annualised loss of £74.3k

During the first 13 weeks of 2011 the average yield variance

experienced has been 35.78% compared to the budget
Lemon Yield
target of 37.9%. This equates to an average weekly loss of
35.8% 37.9%
approx £1.95k or an annualised loss of £78k

During the first 13 weeks of 2011 the average yield variance

experienced across key purees has been approx 10% lower
Puree Yield
than budgeted target This equates to an average weekly
loss of approx £1.5k or an annualised loss of £76k