Operational Excellence – Drive the 5

Operational Excellence – Drive the 5

Drive the Five is a Focused Improvement strategy that will create breakthrough results in your Profitability and journey achieved through Overall Equipment Efficiency losses elimination. In addition to Lean Tools, our team will execute four types of audits to reveal the causes of driving low manufacturing line Efficiencies and Capacity Utilization:

  As-Is Audit

  Multi-Shift Audit

  V-Curve Accumulation Recovery Audit

  Employee Diagnostic

  This will be followed by improvement and sustainment plans.

Chools Competent team of Scholars and consultants will guide your teams through the process using the DMAIC methodology to capture the gains.

Predicted Gains

  5 Points-% improvement on production line OEE.

➤  > 90% Line Capacity Utilization.

➤  Standard Work & Continuous Process Flow.

  Equipped, Engaged and Empowered Workforce.

  Automation Solutions and Interfaces

Our Methodology

Define

✔   Problem Statement : Gap to targeted OEE and utilization

✔   Business Impact and Benefits

✔   Team and Scope

Analyze

✔   Brainstorming , Nominal Group Technique

✔   Problem solving Techniques: FMEA, 8D, 5 whys, BDA, FISHBONE

✔   Gap Analysis- Current OEE VS Glide path

✔   Effort /Impact Matrix , SWOT

Control

✔   Create Balanced Scorecards for tracking

✔   Workforce Training

✔   Visual Controls , Andon , Poka-Yoke, Jidoka

✔   Kanban

✔   MES/ERP — Data Capturing

Measure

✔   $ Value for 1 OEE Over heads /Line costs

✔   Multi Shift Audit – Process Key Performance Measures -OEE, Line Capacity -Non utilized time, Availability losses, performance losses, Quality losses, Equipment downtime.

✔   Employee Diagnostics

✔   Line As -Is Audits

✔   V-Curve Accumulation Recovery studies

Improve

✔   OEE Glide path

✔   Standard Work Strategies

✔   Continuous process Flow strategies

✔   Total Productive Management Plan and pillar teams

✔   Vertical Startups -VSU

✔   SMED/QCO

Related Case Study

Case : Chools was hired by 100 fortune Food and beverage company in MEA Region to drive and develop its Productivity, Lean Six sigma, performance and TPM journey. DT5 was one of the methodologies used to drive OEE Improvement.

Act : Chools Consultants conducted DT5 across 8 plants – 16 production lines. Our consultants inside the DMAIC methodology used the 4 DT5 audits and several Lean problem solving and analysis tools and above all trained the team.

Results : An annual Increase of 13% OEE points was realized for the region, this translated to $5MM – 4.8% of Manufacturing Base spend.

Savings captured encompassed all MOH ; Labor utilities , Maintenance and operating supplies costs.

Operational Excellence – Drive the 5 - Case Study

Case

A Leading Beverage producer with an annual NOPBT of $40MM Partnered with Chools to improve the overall equipment efficiency on their production lines. One of the biggest opportunities was identified as a Size Change over ON ONE OF THE Cans lines that takes 12 Hrs impacting the OEE by a loss of 11% /Yr .  The OEE was 71%, short from the annual operating plan by 9%.

Solution

After looking at the historical Data, we conducted a Pitstop event to measure all tasks and analyze with the line crew the opportunities and improvement plan.  The following was identified

Optimize scheduling to reduce number of Changeovers through improving forecast accuracy measure.

  5 tasks could be externalized.

  Utilization of resources to assist in the Machine Changeover that took the longest time.

  Using automatic tools that reduce the time of redundant tasks: Bolts /screw tightening using an automatic Gun, automatic Filler and labeler crank for heights adjustments.

  5S Changeover parts and Tools to reduce Motion and waiting during the changeover.

Introduce Quick Change over parts.

Elimination of 2 Non added value steps in inspecting the cans after seaming.

New process was tested and standardized and crew trained on.

Results

The Changeover time was to 2.7hrs decreasing the Impact of the changeovers on OEE from 11% to 3%. This reduced the $/Case of the cans line by 20%. Moreover, introducing the new changeover tools reflected on employee morale and safety related to ergonomics.

Case

A Leading Juice producer hired Chools to improve the overall equipment efficiency for their production lines. One of the biggest opportunities was identified as a Cleaning in Place (CIP) activity on their Highest volume PET Line.  The CIP took 5 hours vs. a standard of 2 hours benchmarking with other affiliates   This had an impact of  6% Loss on OEE.  The OEE was 75%, short from the annual operating plan by 6%.

Solution

After looking at the historical Data, we conducted a Pitstop event to measure all tasks and analyze with the line crew the opportunities and improvement plan for the CIP activity, which consists of 5 steps (Cold CIP, Hot CIP, Chemical Sanitization, Cold CIP, External Cleaning).  The following was identified

Optimize scheduling to reduce number of CIP through improving forecast accuracy measure.

Optimize sanitization Matrix.

Modify Piping diameters to increase flow and decrease time.

Optimize temperature of Hot water cleaning step to reduce waiting time for getting filler Hot, which also influenced Fuel and water consumption.

Reduce time of steps validated by Quality team.

Eliminate first Cold step cleaning.

Conduct external cleaning in parallel to last CIP step through installing water nozzles on filler.

Results

The CIP Time was reduced from 5hrs to 2hrs, and number of CIP events were reduced from 156 to 78 times per year. The Loss on OEE contributed by CIP for this Juice line was reduced from 6% to 2%. The $/case for that line and SKU was reduced by 17%. In addition, Water consumption was improved by 11% and Fuel consumption by 5%.

 

 

 

Drive the 5 – Template 1

Drive the 5 – Template 2