LEAN

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 Staff take pride in their workplace – 5S

by default

HukaPak – RESULTS On the job training – initiated by Quality

Staff

HukaPak – RESULTS Reduced Downtime – Right tools for the

job.

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

HukaPak – MORE TO DO Start planning for next season. Strategia

to prioritize again Similar budget. Kanban! MORE VISUAL INDICATORS,

More 5S!, Daily staff briefings. Improve maintenance more – still 2674

bins equivalents of down time.

Staff are the key. Must have and retain key staff!!