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Management Leadership Audit. June 22, 2009. Site Overview. Larry Lebel. Overview of Solon Manufacturing. SKU’s 2,400 Formulas 350 Formats 203 Packaging Lines 22 Processing Vessels 10 Contract-Manufacturers 15 Employees 302 (266 Perm) 2009 Units 100 M In-House
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Management Leadership Audit June 22, 2009
Site Overview Larry Lebel
Overview of Solon Manufacturing SKU’s 2,400 Formulas 350 Formats 203 Packaging Lines 22 Processing Vessels 10 Contract-Manufacturers 15 Employees 302 (266 Perm) 2009 Units 100 M In-House 45 M Contract Manufacturing Average Fill Weight 400 ml
Technical Families • Shampoos – 30M • Conditioners – 51M • Styling – 18M • Aerosols – 32M • Hot Fills – 14M Partners in Excellence
Solon Plant and Miller Warehouse Partners in Excellence
Solon Plant Partners in Excellence
Site History • 1980 Arnie Miller Founded Matrix Essentials, Inc. • 1994 Bristol Myers Squibb Acquires Matrix Essentials, Inc. • 2000 L’Oreal Acquires Matrix Essentials, Inc. • Creation of PPD Haircare Site • 2002 L’Oreal Acquires ARTec • 2003 ARTec is absorbed into Solon portfolio • 2003 Professional Haircolor transitions to Montreal and Perms transfer to Solon • 2004 Redken Haircare transfers from Florence • 2004 Mizani Haircare transfers to Solon • 2007 Perms transition to Montreal, Hot Fills transition to Solon from Florence, Production of Shu Umera begins production • 2008 Production of Pureology Begins Partners in Excellence
Vision 2008 2006 Layout UP1 UP2
Vision 2008 – Final Stage • UP Merger Complete • Perms Transfer to MTL Complete • Warehouse Consolidation Complete • New Entrance Complete • Hot Fills Transfer Complete • Pre-Weigh Relocation – 2009 Partners in Excellence
2008/2009 Accomplishments • OSHA VPP Star Status • 947 days since last lost time accident • 2MM man hours without lost time accident • ISO 9001 • Successful ISIS Launch • Vision 2008 Final Stage • Pureology Brand Transition to Solon • Improved Environmental Indicators • Ecocert Certification Partners in Excellence
Solon 2009 Vision/Challenges • Back to Basics • Safety: Continued Improvement of Culture • Quality: New Quality System/Scoop • Productivity: + 5 Points in OEE • Cost: Manage Costs in a reduced Unit Environment • Execute with Excellence • Optimize the Global Supply Chain • Continued reduction of in-plant inventory • Play a lead role in FG inventory reduction • Low Cost Styling Producer • Solon/Streetsboro Synergies • Employer of Choice Partners in Excellence
2009 Solon Plant Objectives Partners in Excellence
0 5 5 2 9 2008 Safety Performance A total of 5 restricted duty accidents resulted in an ENLARGED RATE = 7.5. • Accident Summary • 2 Slips and falls in parking lot, weather related. • Mechanic injury during troubleshooting, procedure not respected. • Mechanic back injury, osteoporosis. • Trip / Fall on packaging line due to congestion.
Safety Pyramid 2009 Actual → 2009 Goals 0 0 0 2 3 3 3 7 16 17 Assume 500k Man Hours June 17 YTD Lost Time 2 = 4.0 3 = 6.0 RestrictedDuty Recordable First Aid Near Miss L’Oreal Frequency Rate = 18 19
Incident Analysis 2008 vs. 2009 YTD Per Department(% of Total)
2009 Improvement Plan • Compliance - Update physical layout and operational procedures to comply with ORS001 guidelines. • Activities not requiring funding moving forward. 2010 implementation budget in process of development. • Teams being developed for 3rd quarter plan refinement and implementation plan. • Investigation of licensing options for 2010. • Training - Conduct CONA developed "Fundamental SH&E" training for all supervisors, managers and management team members. • SHE Steering committees trained by CONA. – Complete • Planned 3Q training for remaining supervisors and above. • Auditing - Revise auditing program to increase involvement and to include the following: • A revised version of Mesur in process to include BBS for department heads and managers. July Completion.
2009 Improvement Plan (cont.) • Roll out of ORS 002 – SIO’s (Safety Improvement Opportunities) will be tracked and reported to CONA monthly. • Hearing Conservation - Elimination of hearing protection within the packaging cells. • Conduct General SHAP for the site. Planned for 3Q. • Added emphasis on “transparency” through out the site. • Increased communication of all incidents with discussion points for review in team meetings.
Departmental Activities UP – Daniel Roy HR – Pete Ambrosone IQ – Rachel Jarvis Flows – Max Macesich Logistics – Marne Cario
UP safety initiatives • House keeping and safety contest • Between packaging 2 cells, processing and preweigh • Monthly audit perform by UP management • Monthly meeting in processing and packaging team • Review all results with a safety point (results and review of the previous month incident and a monthly safety topic
UP safety initiatives • Monthly audit of production area by supervisors • Monthly safety meeting • Rotate to cover every shift • Hourly people involvement • UP safety improvement action plan • Noise reduction on 2 lines • Line 11 from 86.3db to 82.3db • Line 27 from 85.2db to 83.1db
UP safety initiatives • Pre-weigh relocation • Improving organization of equipment • Reduction of walkways crossing tow motor aisles • Monthly processing one point lesson on safety
Human Resources and Training • HR Staff Meeting Safety Reviews • SHE Monthly Audits • SHE Training Communications • SHE On-Boarding Training for new hires • Maintain the SHE Training Calendar • Manage the development and delivery of SHE Training materials • Maintain the SHE Training Documentation System
Human Resources and Training (Cont.) • Issue SHE Training Tracking and Follow-up Reports • Issue Monthly SHE Training attainment report • Review all safety incidents and determine retraining, disciplinary actions • Oversee the Return to Work Program • Conduct SHE related employee physical testing: Audiometrics, Pulmonary Function, Vision Testing, PIT Operator • Incident Investigation input and remediation training
Industrial Quality • 2009 Safety Initiatives • Focus groups meet monthly – each participant researches and presents work related safety topic • Safe Lifting, Ergonomics, MSDS, Trips & Falls, Forklift Safety, Lab Safety, Chemical Hygiene, Nitrogen Asphyxiation, Dermal Exposure • Designated individuals to perform internal safety audits • Chemical Exposure Monitoring • Yearly review/training of chemical hygiene program
Sub-contracting and Flows • Population: 7 office, 13 hourly • Rigorous forklift reassessment every 3 years • Immediate response to all SOP training needs • Monthly safety meetings • On-going safety action items tracking list • Accountability / report back to staff on progress against safety items • Monthly departmental safety audits • SHAP for major changes • Immediate communication of safety incidents • “Open door” policy on near-miss and suggestions
Industrial Logistics • Population: 13 office employees • Safety is a topic for weekly staff meeting • Metrics definition • YTD performance for the site • Recent incidents/accidents • Analysis of similar risks/situations in our immediate environment • Dangerous/safe behaviors • Suggestions for improvements • Auto-criticism • Time-out in case of Restricted duty or Lost Time accident (immediately following event)