supply chain covington
TRANSCRIPT
SUPPLY CHAIN
LIVE SUPERIOR SERVICE, DELIVER SUSTAINABLE, PROFITABLE GROWTH
SEP 2013
Larry Gibson – Manufacturing Director
COVINGTON
FACTORY TIMELINE
Slim Fast Company acquired by Unilever
High strength waste treatment facility completed
1st Super-shots line in North America installed and operational
Project Yorktown (Slim-Fast Restructuring) Project Lexington (Super Shots Exit)
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03
Project Odyssey (Ice Cream). Engineering starts. Slim Fast RTD production ceases (June 30th)
Ice Cream Manufacturing begins in Space Saver (PIC) on Aug 29th
1st Stickless extruded Line (Klondike) starts on Oct 26th with Reese’s
Moulded Line starts on Dec 15th with Mighty Minis production
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09
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Land O’ lakes (copacker of Slim-Fast ) completes construction and inititates start-up. Building size is approx. 400,000 sq. ft.
Slim-Fast Foods Company assumes ownership of Covington
R&D Pilot Plant Start-up
280,000 sq. ft. expansion (Distribution Center)
Two additional packaging lines installed (doubling capacity).
Processing & canning expanded by 50%
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1996 - 2000 2000 - 2009 2010 - 2011
LIVE SUPERIOR SERVICE, DELIVER SUSTAINABLE, PROFITABLE GROWTH
THE JOURNEY TO ICE CREAM
Infant
Toddler
Adult
Child
Teen
LIVE SUPERIOR SERVICE, DELIVER SUSTAINABLE, PROFITABLE GROWTH
Factory Passport
Building Area: 808,000 sq ft (75,000 sq mt)
Land Area: 3,556,000 sq ft (330,000 sq mt) This image cannot currently be displayed.
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PIC - Packaged Ice Cream
(Breyers)
Stickless Extruded (Klondike)
Molded (Popsicle / Good Humor)
2013 Volumes: 95,016 Liton
PIC: 54,991 Liton (51 SKU’s) Klondike: 21,655 Liton (4 SKU’s) Molded: 18,370 Liton (12 SKU’s)
Production Lines: 14 (pack capacity 206,000) - SS-1: PIC - speed 70cpm - SS-2: PIC - speed 70cpm - SS-3: PIC - speed 70cpm - SS-4: PIC – speed 70cpm - KL-1: Klondike (stickless extruded) – speed 600bpm - KL-2: Klondike (stickless extruded) – speed 600bpm - KL-3: Klondike (stickless extruded) – speed 600bpm - Gram 1: Molded – speed 140 pcs/min - Gram 2: Molded – speed 455 pcs/min - Gram 3: Molded – speed 455 pcs/min - Gram 4: Molded – speed 280 pcs/min - Gram 5: Molded – speed 624pcs/min - Gram 6: Molded – speed 520 pcs/min - Gram 7: Molded – speed 624 pcs/min Mix Room: 2 - PIC Mix Room capacity: 6,000gph* (2 HTST*) - Novelty Mix Room capacity: 6,000gph* (2
HTST) Refrigeration: - Current Refrigeration Load: 5,875 ton - Current Ammonia Load: 125,000 lbs Cold Storage: - Fully Automated – 4,000 pallet positions
2013 Budget: €63.7M at $1,2831: €1.00
STAFFING (Jan/13)
13 Managers 22 Supervisors (WL1) 462 Hourly Employees
178 Temporary Workforce
LIVE SUPERIOR SERVICE, DELIVER SUSTAINABLE, PROFITABLE GROWTH
OVERVIEW
What does a modern foods factory look like? Automation Robotics HMI What does this mean for operators? Math/Analytical Skill/Reading comprehension What Unilever is doing to continuously improve our workforce! OJT BLITZ IRT for All (Unilever University) Advanced Training
LIVE SUPERIOR SERVICE, DELIVER SUSTAINABLE, PROFITABLE GROWTH
GRAM
Consumer Safety, Teammate Safety & Quality
Operators Performing a Changeover
Gram Equipment
Robotic packaging
Automated Case packing
LIVE SUPERIOR SERVICE, DELIVER SUSTAINABLE, PROFITABLE GROWTH
SPACE SAVER
Consumer Safety, Teammate Safety & Quality
Graphical Equipment representation
Breyers Modern packaging equipment
Computer Touch Screen Online statistical controls
Automated Downtime analysis
LIVE SUPERIOR SERVICE, DELIVER SUSTAINABLE, PROFITABLE GROWTH
KLONDIKE
Consumer Safety, Teammate Safety & Quality
Delicious products!
Klondike Robots
Modern Quality assurance equipment
High volume production
Ice Cream Production
LIVE SUPERIOR SERVICE, DELIVER SUSTAINABLE, PROFITABLE GROWTH
MIX
Consumer Safety, Teammate Safety & Quality
In department Mixing Calculations
Batching
High Tech HTST
SUPPLY CHAIN
LIVE SUPERIOR SERVICE, DELIVER SUSTAINABLE, PROFITABLE GROWTH
B ASIC L EARNING I NTENSIVE T RAINING Z ONE TRAINING GUIDES UNILEVER COVINGTON, TN
LIVE SUPERIOR SERVICE, DELIVER SUSTAINABLE, PROFITABLE GROWTH
COMPETENCY CHECK GUIDE
USED TO VALIDATE OPERATOR IS FULLY COMPETENT TO RUN THE TECHNICAL ASPECTS OF
THE EQUIPMENT.
LIVE SUPERIOR SERVICE, DELIVER SUSTAINABLE, PROFITABLE GROWTH
SKILLS TRAINING MATRIX Klondike
Warehouse
Space Saver
Mix
LIVE SUPERIOR SERVICE, DELIVER SUSTAINABLE, PROFITABLE GROWTH
COVINGTON PEOPLE DEVELOPMENT
Mission: Enable factory workers to learn and grow their contributions and rewards by building skills that allow them to meet our consumer and company needs
Deliverables: •Skilled/ Flexible workforce •Highly Engaged workforce •Environment where “Variable Pay” is the •Motivation
Competitive Advantage: •Technical Business partners are running the business day to day. •Employees are the investment and deliver stakeholder returns. •The Vision of the Site and Company is internalized and demonstrated
Prospective Candidates
• Soft Skills • Teamwork • Math • Reading • Locating
Information • OJT Train-
the-Trainer • Basic
Machines Validated Pre and Post tests • CRC • Mechanical
Aptitude
IRT
Maintenance • Shop Math • Operator Core • Fundamentals • Pneumatics &
Hydraulics • Electrical Components • Pump Basics • Valve Operation • Failure Analysis • Gearbox & Bearing • Advanced Pneumatic • Advanced Hydraulic • Advanced Electrical • Pump Maintenance • Intro to Welding • Machine Shop
Practices • Machine Adjustments • Ladder Logic • PLC Advanced
Electrical
Operator • Blueprint Reading • Measurement • Hand Tools • Mechanical
Components I • Bearings &
Lubrication • Mechanical
Components II • Machine
Adjustment
MECHANICAL • Workplace Safety • Preventive Maintenance • Quality Control & SPC • Hydraulic/Pneumatic • Fluid Power Distribution • Piping and Pneumatic • Mechanical Installation • Basic Pneumatic Controls • Basic Hydraulic Controls • Intermediate Pneumatic • Intermediate Hydraulic • Power Transmission
Systems • Advanced Mechanical
MAINTENANCE PROGRESSION
Electrical
M e c h A n i a L
Electrical
C o n T r o l s
O R
Maintenance Technician I Skill Assessment Test
Maintenance Technician II Skill Assessment Test
Maintenance Technician III Skill Assessment Test
AAS Degree Advanced Industrial Integrated
Technology
Certificate Programs
Certificate Programs
Apprenticeship Program
ELECTRICAL
• Workplace Safety • Preventive Maintenance • Quality Control & SPC • Basic Electricity • Power Development • Electrical Power
Distribution • Electrical Installation • Basic Electrical
Controls • Intermediate Electrical
Controls
CONTROLS
• Workplace Safety • Preventive
Maintenance • Quality Control &
SPC • Principles of
Instrumentation • Integrated Process
Control • Integrated Process
Management • Programmable Logic
Controls
Controls
C o n T r o l s
Mechanical
M e c h A n i a L
CORE