LEAN. INTRODUCTION Who is HUKA PAK What/Why LEAN MANUFACTURING BIGGEST BANG FOR OUR $ Measurement...
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Transcript of LEAN. INTRODUCTION Who is HUKA PAK What/Why LEAN MANUFACTURING BIGGEST BANG FOR OUR $ Measurement...
INTRODUCTION
Who is HUKA PAK What/Why LEAN MANUFACTURING BIGGEST BANG FOR OUR $
Measurement Preventative Maintenance & Downtime
Reduction Training
The Results
HUKAPAK – What do we do KIWIFRUIT PACKHOUSE COOLSTORE 5m trays of fruit – 22,000 pallets Main pack
1 April till beginning of June All fruit picked and cooled 3.5m trays packed 1.5m shipped early in April 1.5m TE stored CA/Bin stores Leaves 2.0m trays stored as packed inventory 2007 we repacked 1.5m trays - $$$$$
HUKAPAK – What do we do
2 shifts – 21 hours a day Staff turnover during mainpack –
100% Staff turnover between seasons 90% Only 10% of staff with experience Multi cultural – problems with
consistency etc
HukaPak – WHAT IS LEAN Toyota Way, 6 Sigma, TPM ,TOC etc etc FOCUS ON WHAT ADDS VALUE TO YOUR CUSTOMER –
Eliminate any waste Forget or don’t worry about everything else
Long term Philosophy Process Excellence Focus on Processing staff – People are Key Problem Solving
Spend money on what matters Making the job more enjoyable (maybe easier?) Don’t spend money on anything else
HukaPak – WHY LEAN Need to change attitude of key staff – No
more rip, shit or bust Put measurements in place that tell us if we
are doing OK. Weekly Daily Hourly
Reduce unnecessary costs – Repacking $1.5m
Reduce down time. 10mins = $500 in wages + $500 in lost opportunities!!!
HukaPak – BIGGIST BANG
Budget of $32,000 Worked with LEAN consultants to
prioritize Eliminate waste by finding out what
really matters! Small improvements in 2 months!! NZT&E funded $10,000 so far.
HukaPak – MEASUREMENT How do we measure quality?
Fruit loss and Repacking – difficult 3 months after the fact!
How do we measure efficiency? Trays per hour – How about fruit quality in the
bin? Downtime big issue – what really adds value?
What's more important Quality or Efficiency Some staff did not know!
HukaPak – MEASUREMENT How do we measure quality? Traffic light system!
Measure time we are on Green, Orange and Red. Put in systems to get us to Green!!
HukaPak – MEASUREMENT How do we measure
efficiency? Not Trays per hour –
Too many variables Bins processed per
hour. Cannot compromise
Quality. SO upper limit!
Hourly output targets – 34 bins an hour Gold fruit – GREEN light
Each operator has these displayed!!
2008 GOLD OUTPUT
0.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
40.0
45.0
DATE
BIN
S P
ER
HR
CUM BINS/HR
TARGET
DAILY BINS/HR
HukaPak – MEASUREMENT
How do we measure efficiency? Downtime big issue – what really adds
value? Grader 1 return per tray - $6.00 Grader 2 return per tray - $4.00 Grader 3 (Class 2) return per tray – 40
cents. Plus opportunity cost of G1 & G2 not
running!! So second project!
Preventative Maintenance & Downtime Reduction
Preventative Maintenance We have always had a Maintenance Plan
YES BUT Which equipment has the highest risk and cost
to our efficiency – G1 Bin Dump!SO REDUCE RISKS
And REDUCE IMPACT Staff to work with the Maintenance contractors
both pre season and in-season Replacement parts on site or in contractors van Expert on site each day between shifts Contingency plan if all else fails
Preventative Maintenance & Downtime Reduction
Preventative Maintenance SMART SPUD Compac’s accelerometer that we got
going. Measures impact points. Grader 1 excellent except for part bins
on Bin dump! – Terrible Grader 2 not so good and we can now
work on where the issues are.
Preventative Maintenance & Downtime Reduction
Downtime Reduction - Goals Reduce to below last seasons Prioritise projects – G1 Bin Tip!
- Grower & Receipt Changes
Don’t stop G1 & G2 if G3 has a problem!
HukaPak – TRAINING Pre-season training for Supervisors.
How to Supervise. Better pre-season training for staff
Do it right first time! Simplify Inductions
Made video so inductions can be done at 6.00am and 8.00pm
Standardise on the job training
Stacking dept Induction for new staff.
Reinforce Daily!
H&S BRC House Rules
Closed shoes only Long hair out of sight. Phone in early if sick!
No loose clothing Hats / hairnets. Turn up on time!
Hands clear of machinery e.g. belts
Jewellery: wedding bands and sleepers only
NO physical or verbal abuse against others
Pick up fruit on floor Clean fingernails / no polish NO phones/Ipods/hoods
Wear all PPE provided NO Food/chewing/drinks NO take home fruit
No going in restricted areas Always wash hands at breaks Always ask questions!
Emergence evacuation Personal hygiene Treat others with respect
NO riding on Jiffy's NO Aprons in toilet Always clock in/out
NO Running in Pack-house NO Aprons in canteen Smoke only in smkoing areas
NO dropped pallets from jiffy's Wear blue plasters on cuts NO Alcohol or Drugs
Wear snoods as appropriate Back from breaks on time!
Wear Viz vests as appropriate Clean during downtime
Key Induction Training Points What to look for!
Check size on E.A.N label MATCHES Drop Size.
Ask questions to check understanding.
Check first stack configeration against standard. Look for body language
Always 'PLACE' boxes on stack. Listen for the correct answer
Only lift a maximum of 4 trays or 2 MB's Give clear instructions
Place bungie cord 3/4 of the way up the pallet. Coach
Notify supervisor about wrong, lost, unused or ripped labels. Monitor
Report any machinery faults to supervisor!
DOING IT... RIGHT FIRST TIME!
KPI: UPTIME - SAFETY - "0" DEFECTS
Packing dept Induction for new staff.
Reinforce Daily!
H&S BRC House Rules
Closed shoes only Long hair out of sight. Phone in early if sick!
No loose clothing Hats / hairnets. Turn up on time!
Hands clear of machinery e.g. belts
Jewellery: wedding bands and sleepers only
NO physical or verbal abuse against others
Pick up fruit on floorClean fingernails / no polish NO phones/Ipods/hoods
Wear all PPE provided NO Food/chewing/drinks NO take home fruit
No going in restricted areas
Always wash hands at breaks Always ask questions!
Emergence evacuation Personal hygiene Treat others with respect
NO riding on Jiffy's NO Aprons in toilet Always clock in/out
NO Running in Pack-house NO Aprons in canteenSmoke only in smkoing areas
NO dropped pallets from jiffy's
Wear blue plasters on cuts NO Alcohol or Drugs
Wear snoods as appropriate
Back from breaks on time!
Wear Viz vests as appropriate
Clean during downtime
Key Induction Training Points What to look for!
Placing of fruit gently in boxes! Ask questions to check understanding.
Check packaging, plix, plastic matches fruit size.
Look for body language
Wrap fruit ensuring plastic is fully enclosed, ends tucked and folded under.
Listen for the correct answer
Place and level fruit gently in MB's and ML's.
Give clear instructions
Make sure lid is fully secure! Coach
Report any machinery faults to supervisor! Monitor
DOING IT... RIGHT FIRST TIME!
KPI: UPTIME - SAFETY - "0" DEFECTS
HukaPak – RESULTS Reduced Downtime
Bin Dump 1 – 50% reduction from 2007 Bin Dump 2 – 75% reduction Grader 1 – 30% reduction Grader 2 – 75% reduction Grader 3 – 200% reduction – we did pre-season
maintenance! Grower Changes – 300% reduction.
Result – 14hrs downtime saved G1 Result 16hrs downtime saved G2 That’s 1318 bins processed extra.
HukaPak – RESULTSGOLD RK PERFORMANCE 2008 VRS 2007
0
100000
200000
300000
400000
500000
600000
14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
ISO WEEKS
TR
AY
S
2007 RK
2007 FL
2008 RK
2008 FL