WS Packaging Group, Inc. Internship Program

Summer 2013

Mark BartholdInternship Report Out

Operations/Algoma, WISummer 2013

• Originally from Ham Lake, Minnesota– Graduated from Blaine High School

• College – University of Wisconsin Stout- Entering last 2 semesters with graduation in May. 2014- Completed degree in B.S. Business Management- Pursuing a degree in Packaging- Member of the IoPP (Institution of Packaging Professionals)

• Past Work Experience – DIAGEO. (May. 13- Dec. 13)Packaging Intern Technology Team - Three sight qualification on Smirnoff Ice to role out lightweight crowns - Liquid Nitrogen dosing PET Smirnoff cocktail bottles - Caption Morgan label transition process - Bottle integrity gauge development for all internal glass bottles

Introduction

Intern Projects:-Reduce setup time MA-9 Longford -Reduce physical setup time Comco 5-Install Gannicott table Comco 1-Ink room Kaizen and data collection

Tasks:Reduce the physical changeover time • Observe press and prepress to understand the process• Identify areas on setup that take the longest• Brainstorm ideas to improve the setup to reduce press downtime

Improve Ink mixing/ matching process• Develop ink tech standard work• Identify areas to improve ink FPY• Collected data to validate purchasing the perfect proofer and including it into the drawdown process

Project Responsibilities

MA-9 Longford setup reduction •Determine the best solution to long setups was to change the setup from internal to an external operation•Implement dial gauges and quick turn knobs•Develop a matrix's to reference when performing setup•Implement change and enforce standard work process•Setup reduction from 45min to 5min, savings of 40min per setup internal•Labor savings of $7,800 annually (40min x .58 x 340 of jobs a year)

•Potential press revenue $122,300 annually (40min/60 x $540 press rate per hr x 340)

Action Taken to Achieve Results

Improvements and Outcomes

Comco 5 Physical Setup Reduction •Determine best solution was to implement new pre-stage tables that eliminate added walking time.•Designed new bench formatting, new pre-stage tower and determine proper placement •Setup reduction from 170min to 120min savings of 50min per setup•Labor saving of $11,774 annually (50min x $.58min x 406 setups a year) •Potential press revenue $152,250 annually (50min/60 x $450 x 406 setups a year)

Action Taken to Achieve Results

Improvements and Outcomes

Comco 1 Gannicott Table Installation •Best solution to improve fpm on Birchwood was to install Ganniott feeder table.•Allowing the tailor more room to assemble and package the sheeted target. •Increased press speed from 185fpm to 250fpm, a 35% increase•Potential press revenue of 586,000 (9,285,572gfpy / 4,085 hr in a year x

35% x 410 press rate per hr) •Potential Birchwood sales increase of 1,405,000 (4,016,446 sales per year x 35%)

Action Taken to Achieve Results

Improvements and Outcomes

Ink Room Perfect Proofer Labor Saving •Worked on Kaizen team to create standard work and determine ink room focus points.

•Worked with Oliver to double the drawdown capability of the Perfect Proofer in the ink room.

•Total Labor Savings of $65,358

•Mark- Labor Savings of $32,679

•Oliver- Labor Savings of $32,679

Action Taken to Achieve Results

•How to use and implement lean manufacturing tools efficiently through SMED events, time observation studies, spaghetti diagrams, 6s events and Kaizens.

•A process is easier to implement and sustain if it is simplified and not over complicated.

•Drive deadlines and hold people accountable to deadlines promised.

•Drastically increased team working skills and problem solving techniques.

•Have a plan of attack before starting a process because if you don’t you will end up wasting time and resources.

•Time management is very important and goes hand-in-hand with keeping organized.

Key Learnings – Job Related

What I was looking for in the internship: -To expand my background on the printing industry and develop a background in lean manufacturing.

What I got from the internship: -A complete understanding of the flexography process and a in-depth experience in lean manufacturing, through Kaizen, SMED events, time observation studies, spaghetti diagrams and 6s events.

My Expectations and Experience

Final Comments

Overall Saving Across Projects

Labor Savings $52,253

Potential press revenue $860,550

TOTAL Savings $912,803

Questions?