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LEAN

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

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LEAN

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  1. LEAN

  2. INTRODUCTION • Who is HUKA PAK • What/Why LEAN MANUFACTURING • BIGGEST BANG FOR OUR $ • Measurement • Preventative Maintenance & Downtime Reduction • Training • The Results

  3. 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 - $$$$$

  4. 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

  5. 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

  6. 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!!!

  7. 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.

  8. 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!

  9. 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!!

  10. 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!!

  11. 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!

  12. 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

  13. 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.

  14. 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!

  15. 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

  16. HukaPak – RESULTS • Staff take pride in their workplace – 5S by default

  17. HukaPak – RESULTS • On the job training – initiated by Quality Staff

  18. HukaPak – RESULTS • Reduced Downtime – Right tools for the job.

  19. 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.

  20. HukaPak – RESULTS

  21. 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!!

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