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Group CI Manager, Newsprinters
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George DonaldsonGroup Continuous Improvement Manager
Chasing the
Lean Transformation
Who We Are &
What We Do
Newsprinters
What we do
How we do it
Raw Materials (Paper, Ink, Font and Plates) Preparation Plate Making
Paper HandlingPrinting PressesPost Press - PackagingNewslogistics
To be recognised as the best
Newspaper Manufacturer in the World
Newsprinters Vision
TheNewsprinters
Road Map
NCIS 5 Year Road Map2010NCIS - TPMExecutive Team Strategy SessionsPlanning and Pilot SessionsWorkshop Development
2010 2011 20132012
2011TPM – Phase 1Site CommunicationsInk Room, QP2 & QP3 WorkshopsGroup Visual Standards & Audits
2012TPM – Phase 2QP4 & QP5 WorkshopsSite Awareness SessionsPolicy Deployment – PilotNVQ BIT - Pilot
2013TPM – Phase 3QP6 & QP7, QP9 & QP10 WorkshopsPolicy Deployment – GroupNVQ BIT – SHINGO Pilot @ Eurocentral
2014 2015
2014TPM – Phase 4QP1, QP11 & QP12 WorkshopsKaizen WorkshopsSHINGO Challenge @ Eurocentral
2015TPM – Phase 5Group StandardsManagement TrainingShingo Start @ Knowsley
The Shingo JourneyMay 2012September 2010 July 2014
August 2014
ToolsPrinciplesSystems
“Management must change fundamentally, transform its attitude towards the worker,
understand variation and focus on the system”
(Deming W. E., 1986)
W. Edwards Deming
“The forces along the top rob people, and the nation, of
innovation and applied science. We must replace
these forces with management that will restore the power of the individual”
(Deming W. E., 1994)
W. Edwards Deming
15
The Newsprinters Way
Newsprinters Continuous Improvement System
Systems That Encourage The Right Behaviours
Systems Where Everyone Is Engaged
Total Productive Manufacturing
Total: All Staff - All Business Partners - All Levels – All Committed
Productive: All Working together - All Driving Continuous Improvement
Manufacturing: All Processes - All Activities - All Equipment
Holistic Systems
Systems Where Everyone Is TrainedSharePoint, PDCA & Process Mapping
Problem Solving, FMEA & KANBAN
Project Planning, Change Control & SMED
Workshop 1 – 3 Review
ISO Systems, Internal Audits & Visual Standards
Maintenance Best Practices (RCM vs TPM)Asset Care Review & Kaizen Cycle
OEE, Quality Management & Test
Asset Criticality, 7 Wastes & CI Tools
It Wasn’t Always Good
5S – So you can see the waste
5S – Make it obvious
Visual Standards Across The Group
EurocentralKnowsley
Broxbourne
The Newsprinters Audits
Staff Audits Daily:• Use Area Audit Form and audit the work area assigned.• Complete the form noting any issues and highlight 9001-14001-18001 concerns to Manager.
Visual Staff Audits - Daily
Systems Where Everybody Audits
Daily ~ Staff and Frontline Managers Weekly ~ Managers Monthly ~ Senior ManagersQuarterly ~ Executive Directors
Where Every One Has PAL
NewsprintersAccomplishments
Environmental
Lean Manufacturing
Lean Manufacturer of the Year
Printer & Environmental Company of the Year 2011
Printer of the Year - 2013
Printer of the Year - 2014
Recognised Lean Manufacturing Facilitators
UK’s 1st Shingo Prize Winner – 2014
Shingoor
Terry
