Gluer project Slough-FINAL DRAFT1

Company Private & Confidential ASG Worldwide Page 1

Project – Gluing Speed Optimisation to

increase capacity


Project Scope

Use JAG 900 as the pilot line on O-Rings

only, then roll out to all lines and other

product families and machines

To increase production speeds and efficiencies on all gluers and all products within Slough

facility


Business Case:

•Customer Service Level is adversely affected at Q3 and Q4 due to lack of capacity at

high seasons

Capacity may be improved using Lean Six Sigma principles and

methodologies to increase throughput of individual machines on

the Finishing line. A 15% increase in speed will improve Service

Level to our customers and contribute to the bottom-line.


Goal Statement

•Improve Customer Service Level to over 90% at Q3 and Q4 by maximising Gluing

machine efficiencies

To use DMAIC (Define, Measure, Analyse, Improve and Control)

process to improve gluing speed, hence improving throughput

and Service Level to our customers.

Project Teams


Project Sponsor

Tony Garnish

CEO EU

ASG Group

Technical Project Support

Lance Blizzard

EU Technical Director

Lean Project Support

Fudgie Maynard

EU Process Improvement Director

Project Sponsor

Mark Bonser

General Manager

ASG Slough

Project Owner

Manny M’banugo

Lean facilitator

Project Manager

Tony Shipp

Finishing Supervisor

Project Manager

George James Factory Manager

Project Team Members

Emi; Tom

Live Google document to capture project actions, status & progress.

High Level Process Map (SIPOC) for Gluing machinesProcess: Process Owner:

S I OSuppliers Inputs Outputs

Ink cured product and a healthy

machineSteps Quality product on time in full Dispatch and Distribution

Tony Shipp

CP

Gluing of Die-cut boards

Process

Dispatch and Distribution

Customers/Stakeholders

Folded cartonsDie cut boards from

bobst stationDie-cutting Bobst station

Gluing of Die cut boards on the Finishing Line

Receive job from

Die-cutting

Station + Job

bag

Run and Box

Product, then

sign-off job bags

Log in job

number on

Imprint + Set-up

machine

MakeReady

Set Imprint on

Run + Print Box

label

Collect samples

+ file

Critical Factors to Effective Gluing

•Safety

•Quality Checks

•Experienced operators

•Equipment health

•Material quality

•Good Workplace Organisation

•Current Manufacturing Practices

•Make Ready

•Scheduling


Pressroom

100% Cure achieved on press

Measurement equipment in place

Procedure compiled and sent to team


Gluer

Identify baseline speed (done)

Identify Products in scope of project (done)

Build Matrix of all gluers, products etc (done)

Build Optimum labeling system

Build/develop bible of gluing specifications per job (Done – new jobs only at present)

Identify gaps (gap analysis) – (Done --- Quality checks; Quality of product to station;

planning of jobs to machines; inter-stations and interdepartmental communication;

staffing knowledge and training of Agency staff;

Define


Measure, Analyze and Improve Stages

Baseline Measure from 01/01/13 to 31/12/13 (Imprint Data)


Measure, Analyze and Improve Stages

Stage 1 – Improvement April 2014 (Imprint Data)


JAG 900– KPI APRIL 2014

• PERFORMANCE vs TARGETS

Jag 900 Average Running Speed 2014

-

2,000.00

4,000.00

6,000.00

8,000.00

10,000.00

12,000.00

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov DecAverage running (copies per hour) Running target (copies per hour)



Jag 900 Average Make Ready 2014

0.00

5.00

10.00

15.00

20.00

25.00

30.00

35.00

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov DecAverage make ready (mins) Target make ready (mins)




Jag 900 Copies Per Manned Hour 2014

-

2,000.00

4,000.00

6,000.00

8,000.00

10,000.00

Jan

Feb

Mar

Ap

r

May Ju

n

Jul

Au

g

Sep

Oct

No

v

Dec

Copies per manned hour Copies per manned hour target




Jag 900 Lost Time 2014

0%

2%

4%

6%

8%

10%

12%

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov DecLost time Lost Time Target



Achievements to Date

Comparative Analysis of 2013 averages and Project period (01/04 onwards)

AVERAGE RUNNING SPEED ON JAG 900 (2013) AVERAGE RUNNING SPEED ON JAG 900 (APRIL 2014

..)

4166.52 10955.12

AVERAGE SHEETS PER HOUR ON JAG 900.(2013) AVERAGE SHEETS PER HOUR JAG 900 (APRIL 2014..)

3436.44 9221.37

AVERAGE MAKE READY MINUTES JAG 900 (2013) AVERAGE MAKE READY MINUTES JAG 900 (APRIL

2014…)

21 9

AVERAGE OVERALL MAKE READY MINUTES

FINISHING 2013

OVERALL MAKE READY MINUTES FINISHING APRIL

2014….

30 18


Comparative Analysis of 2013 averages and Project period (01/04

onwards)

Over 260% increase in Average Running Speed, so far on

JAG900

Nearly 270% increase in throughput

Average M/R time reduction of 12minutes on JAG900

Overall average M/R improvement of 12 minutes on all

machines, compared to 2013.

WE ARE NOW ROLLING OUT THE EFFORTS TO OTHER

MACHINES – STARTING WITH JAG-105 (09/05/14)


Gaps

Training for new Agency staff (approved by Mark B)

Quality Checks need to be conducted upstream. Devise a culture of 'stop and fix' issues at

each station before moving product downstream

Tighter supervision upstream and on late shift

Grouping jobs in product families and allocate to the most efficient and effective machine for

job family (matrix build in progress)

Optimize staffing and skills levels (In progress)

Gaps highlighted to ensure continual improvement


Thank youSubtitle and/or date

Documents

Gluer project Slough-FINAL DRAFT1