employee engagement delivers great results at weetabix...an internal improvement champion has been...

Employee engagementdelivers great results at Weetabix

The Lauras team have supported the Bars business unit atWeetabix in achieving tremendous improvement through strongemployee engagement. The implementation included trainingand coaching of operators, technicians and front line managers,coupled with a series of impact workshops that had multiplestreams of activity. Results included; improved output by over50%, reduced waste by 80%, improved product quality andreduced energy usage.

The unit management team, supported by Lauras consultants,played a crucial role in driving the improvement programme forward.They built a detailed improvement plan and set area improvementcharters. All personnel were trained in Rapid Lean tools and 3supported 5-week impact workshops kick started the journey.

The workshops started with training in Rapid Lean improvementtools, followed by operators investigating and fixing problems and helping to ensure good solutions that stuck. Workshop topics included:

• Optimisation of accumulation and line control• Eliminating speed restricting problems• Reduction of product weight variation• Reduction of waste and giveaway• Changeover reduction• Implementing a fixed schedule, producing every 2 weeks• Reducing Mean Time to Repair (MTTR)• Implementing a breakdown investigation system

Alongside the workshops and improvement activity, daily/weekly/monthly review processes and associated metrics/scorecards were established.

© 2008 Lauras International (Europe) LLP. All rights reserved

Kitchen Slab Forming 1st Cool Slitter Spreading

Table Guillotine Decormatic Enrober 2nd Cool HSM Schubert

Casing

Kappa

Capacity 1777 2556

1405 974

1082 1000

1350 1000

1668 2700

1280 1500

Throughput 913 913

857 857

857 857

857 857

621 681

680 728

Capacity Profile

Finding Throughput

Bottlenecks

Finding Throughput

Bottlenecks

Finding Throughput

Bottlenecks

Finding Throughput

Capacity Profile

Capacity

Throughput

Kitchen Slab Forming

Capacity 1777 2556

Throughput

Slab Forming 1st Cool Slitter Spreading

T

1405 974

1082

Spreading

able TTa

Guillotine Decormatic

1082 1000

1350

Enrober 2nd Cool HSM

1000 1668

2700

HSM Schubert Casing

Kappa

2700 1280

1500

© 2008 Lauras International (Europe) LLP

Throughput

All rights reserved .


Throughput 913 913

All rights reserved

Page

857 857

1

857 857

857

857 621

681

681 680

728

Implementation

A

WINNER

ResultsThe team are very proud of the results achieved with this project:

• Output increased by 52% year on year

• Total savings in excess of £1m

• Labour cost / case decreased 8%

• Accumulation increased by 121% without capital spend

• Line speed improved from ~640 bars per minute (bpm) to 900 bpm (+40%)

• Broke multiple production records (shift output, daily output,weekly output)

• Waste reduction of 80%

• Giveaway improvement from 10-15% (product dependent)down to ~5%

SummaryFor the Lauras team it’s vital that striving for operationalimprovements and great results is an ongoing process, long afterour more ‘hands on’ involvement in a particular project hasfinished. An internal improvement champion has been appointedand trained and provision has been made for on-going knowledgebased mentoring. For the Cereal bars business unit theircontinuous improvement journey has been one of understandingthat the most precious resource is their people and that if they canengage and support them in the right way, impressive improvementwill follow. Very significant behavioural change has been achievedand multiple streams of activity have been in place.

“With the support of the Lauras team, the Barsbusiness unit has made great strides forward withsome exceptional results. It has been gratifying towitness the confidence and capability of thepeople grow paralleling the rise in plantperformance. I look forward with great optimismto the continuing journey and an ongoingpartnership with Lauras International”

Mike Parsons, Head of Manufacturing, Weetabix

© 2008 Lauras International (Europe) LLP. All rights reserved

Page 4

The De-Bottlenecking

Method

800

AP4 Cereal Bars

Date

25/11/2010

Target Actual

Production

Downtime

Corrective Actions

ts

0

0 Time Target Actual

% Min

Description

Description

0

0 07-08

916 600

66%

Kappa 3 and Sch 1&2 playing up all shift.

1

0 08-09

916 1080

118%


s Closed

All

09-10 916

960 105%


Target Actual

10-11 916

960 105%


Held

0

0 11-12

916 1200

131%


ime %

99.50% 100%

12-13 916

1080 118%


Fs

0

1 13-14

916 960

105%


Target Actual

14-15 916

1200 131%

ance to Plan

95%-105% 161%

Shift 7328

8040 110% 20

4%

Other -14%

rmity to Plan

95%-105% TBC

Waste Area Kgs

Top 3 Waste Causes Kgs

Corrective

Actions

Bar Weight Issues & Actions

le

Target Actual

Dry Ingredients

176

ness & Absence

2

Former 52

69

Production Made

Agency FTE

5 Guillotine

69

63

Cases Comm Code Description

Target

vertime Hours

0 Bar quality

Total Waste Kgs

402 Cases Left to do 1242uk. 8064Int

8040 7306

07306 - ALP STR&YOG BAR

10X5X29G 5000

otal Headcount

12 14

PDS belt 42

SQL Output Kgs 11658.00 Enough Stock? Y/N Check

Cost

Target Actual

HSM 63

Giveaway %

TBC Estimated C/O Time 2am Friday

Output/Bars

402000 Floor

Manual Count

8040

Average

Line Speed 2.9

Throw away % 8%

3% Wrapped bars 176

SQL Count

8040 Planned Training/hours

Labour Cost/Case £0.29 £0.16 Binder

WMS Count

8040 Achieved Training/hours

110% Efficiency for the

Shift. Record score.

402,000 bars.



Method


ts

arget

800

0

0

0

argeTTa

Actual

0

ime T

0

07-08

1

08-09

Production

AP4 Cereal Bars

916 600

66%

916 1080

18%

105%

argeime

arget TTaActual

%

07-08

08-09

1

Downtime

Kappa 3 and Sc

Kappa 3 and Sc

Min

Des

Kappa 3 and Sch

Kappa 3 and Sch

scription

Date

scriptio

h 1&2 playing up all shift


h 1&2 playing up all shift.


Actions

1/2010 0

Descriptio

25/1

Corrective

Description

s Closed

Held

ime %

Fs

ance to Plan

All

0

100%

1

161%

arge

arge

09-10

arget TTa

Actual 10-1

0

1-12 1

99.50%

12-13

0

13-14

arget TTa

Actual 14-15

95%-105%

Shift

09-10 916

960 105%

916 960

105%

916 1200

131%

916 1080

18%

916 960

105%

916 1200

131%

7328 8040

10%

1 10-1

1-12

12-13

13-14

1

14-15

Shift

1

Kappa 3 and Sch

%

Kappa 3 and Sch

Kappa 3 and Sc

Kappa 3 and Sch

Kappa 3 and Sc

Kappa 3 and Sc

Kappa 3 and Sch

Kappa 3 and Sch

Kappa 3 and Sch

Kappa 3 and Sch

20

4%

10% Ef1











fi iency for the% Efff

rmity to Plan rmity to Plan

le

Agency FT

le

Absence ness &

Agency FTE

vertime Hours

otal Headcount

Cost

95%-105%

2

5

0

14

Actual

arge

arge

TBC

arget TTa

Actual

12

arget TTa

Area

52

69

42

63

Kgs

Dry Ingredients

Bar quality

aste W

Kgs op 3 op 3 WTTo

Dry Ingredients

Former

Guillotine

Bar quality

otalTTo

PDS belt

SQL

HSM

Giv

aste Cau

aste Kgs

Output Kgs

veaway %

W

aste Kgs otal W

Cases Left to do

Output Kgs

Enoug

veaway %

TBC Estimated C/O T

verage A

10% Ef1 Shift. Record score.

1242uk. 8064Int 8040

Check

2am Friday

1

gh Stock?

2am Friday

ses LeY/N C

ugh Stock?

ime 2

Estimated C/O T

verage

ficiency for the% Efff

Shift. Record score.

402,000 bars.

Actions

7306

5000

6

ssues &t Issues &

ion Made

ode Description

argTTa

STR&YOG BAR

ALP07306 -

10X5X29G

arget

5000


Output/Bars Output/Bars

Throw awayO

Throw away %T

Labour Cost/Case

All rights reserved

.


%

402000

3%

£0.16

8%

Labour Cost/Case £0.29

All rights reserved

Page

Floor

176

rapped bars

Manual Count

rapped bars W

SQL

Binder

WMS Count

4

Manual Count

8040

8040

8040

0 Line

0

Count SQL

Planned T

WMS Count

Achieved T

verage 2.9 9

e Spee

raining/hour

e Speed

raining/hours d TTr

raining/hours

ed TTr

nternational (Europe) LLP. All rights reserved

Page 5

e

PCS Step 2 – The Cause




e

e

nternational (Europe) LLP

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nternational (Europe) LLP

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5

Lauras International:

www.laurasinternational.com

employee engagement delivers great results at weetabix...an internal improvement champion has been...

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