View
5
Download
0
Category
Preview:
Citation preview
About Omniblend
A contract dry powder food manufacturer specailizing in the Sports and Nutrition markets.
- Domestic and Export Markets
- Milk based protein powders for both sport performance and weight loss.
- Certification in HACCP, BRC, DFSV, Export, Organic, Halal & Kosher.
- Product development and various production capabilities.
Identification of Value Adding and Non-Value Adding Components
Business Value Stream Map (Current State)
Identification of Value Adding and Non-Value Adding Components
Business Value Stream Map (Future State)
5S PROCESS
Set up Teams into areas
Set up Communication Boards and Regular Meetings
S1: Sort
S2: Set
S3: Shine
S4: Standardise
S5: Sustain
S1: Sort - throw out what‟s not needed
- keep what is - white tag and hold if not sure, then decide in meeting.
S4: Standardise - lock in improvements so that people don‟t fall back into old ways
- Standard Procedures and Photos
S5: Sustain
Ensure that 5S is ongoing: - regular meetings - training new staff - remember we can always get better
Improved Arrangement of Office Area
Before Shelving in office area had items stored at
random
After Shelving in office area is labelled in order
to define storage of items
Introduction of Auto Bag Filling for Blending
Before Blended powder dispensed into bags
manually – very labor intensive process
After Blended powder automatically dispensed
into bags – less labor intensive
Introduction of Auto Filling for Packing Lines
Before Hoppers were filled using 20 Kg bags
making it very labor intensive with OH & S and cleanliness issues
After Hoppers are now filled using Bulk Bags,
alleviating issues with loading and cleaning
Manual and Auto-Lidding
Before Lids are closed manually by using a
mallet to force the lids tight
After Lids are now closed through an automatic lidding machine – reducing manual labor
Introduction of Standard Glove Holders
Before Gloves placed on tables – can be
relocated and not always in the same spot.
After Gloves now placed in standard glove
holders – gloves always in the same place and easily located.
Labelling of Shelving for Ingredients
Before Ingredients placed on shelves with no labelling - no control over where they
are stored
After Shelving is now labelled and has provided
an easy visual tool for storage
Standardisation of Retention Sample Labeling
Before No defined process for what information
to display.
After Standard label – consistent information
provided for each sample.
Standardising Retention Sample Room
Before Retention sample room cluttered with
little organiation
After Retention sample room now has all boxes
of samples labeled and categorised
Project by Greg Lacey.
Incoming products process reviewed to include:
- standard inspections
- logging of non-conformances, and steps taken with supplier to rectify
Error Proofing
Project by Davina Pritchard
- Determined baseline times
- Determined tooling requirements and conducted 5S
- Designed balanced labour for changeover process
- Used whiteboards for communication
- Developed work instruction sheets to standardise process
Quick Changeover
Vative assisted us to measure culture & morale after the 10 month program, and we compared it to the measurement before.
We saw improvements in the areas of:„Staff involvement‟,„Empowering Staff‟ and their „Satisfaction‟ coming to work
Staff are now more aware knowledgeable of „waste‟ and „Continuous Improvement‟ and have access to resources on how to implement the changes.
There is always “low hanging fruit” that can be capitalised on. Even years after the training program Omniblend can still find these capabilities if they are addressed.
Culture and Morale
POTENTIAL IMPROVEMENTS / CHALLENGES:
Time dedication
Commitment from top level Management
Organisation alignment
OVERALL OUTCOME:
Awareness and knowledge of lean principles – up-skill of staff.
Increased Capacity – new clients.
Improved Process Efficiencies
- Semi automation of particular processes.
- Standardisation of processes.
- Better utilisation of resources.
Reflections on Doing Lean
Recommended