Problem Description

The process of saucemix delivery is highin Non-Value Adding (NVA) activity(98%). The process highlights longdistances travelled (3,350 miles)resulting in potential high risk accidentsand high labour content ofapproximately £22,032 PA over 3 shifts.

What does good look like?

A process that delivers the saucemix to the machine autonomouslythat is safe and easy to clean beingquality friendly. This will result inzero accidents, zero downtime andsavings in excess of £123,000 over 3years.

Team

Kevin Brown Mark Walsh Amy LangridgeDavid Stephens

MeasurablesMeasurement Current Actual

Cost £41,000 PA £123,000 savings over three years for 3 lines

Quality Relies on Two Eye Check Manual input into system Transport & Load issues

Two tier delivery system to avoid cross contamination remove unnecessary wastage

Safety 14 near misses and 1 serious safety breach resulting in employee dismissal

Zero accidents and near misses for this task

Productivity Time consuming delivery system safety issues and intensive manual labour

Automated delivery system limited labour input.

Deliverables

Improve environment, quality, cost & delivery of safety

Meet cost saving targets

Implement sustainable saucemix delivery process

Cost V Benefit

LOW 3 6 9MEDIUM 2 4 6

HIGH 1 2 3LOW MEDIUM HIGH

CO

ST

BENEFIT

Critical success factorsQuality acceptanceSafety acceptanceErgonomically compliantBuy in from works directorWorkforce acceptanceUnion agreementMaintenance engineeringEnvironmental impactCost saving focus (Labour, Waste &

Materials)

Action Plan

Item Action Responsibility

Flow process Map out flow process Completed by team

Equipment Cost out and spec delivery system

Budget quote received based on one line

Communication Consult with stakeholders

Review Present findings to management

Decision Finalise decision process

Progress Chart

COSTS156metres travelled studied on Line 3

214 secs to do this task We estimated costs based on doing this twice an hour

Cost per hour:156m x 2 = 312 metres / per hour

214 secs x 2 = 428 secs per hour (7.1 min per hour)Cost for one shift

312 x 8 = 2,496 metres per shift7.1 mins x 8 = 56.8 mins per shift

Cost per 24 hour period2,496 x 3 = 7,488 metres per shift

56.8 mins x 3 = 170.4 mins (2.84 hours per 24 hour shift)Cost for 3 lines for 24 hour period

7,488 metres x 3 = 22,464 metres2.84 hours x 3 = 8.52 hours

Costs for 3 lines for 5 day week22, 464 x 5 = 112, 320 metres

8.52 hours x 5 = 42.6 hours per weekAnnual cost

112, 320 metres x 48 = 5, 391, 360 metres or 3,350 miles42.6 hours x 48 = 2,448 hours per year

Based on average day salary of around £9 per hour:2,448 x 9 = £22,032

Potential Estimated SavingsLeasing for 4 IBC lifters – £10,000

Training for lifters - £2,000Maintenance of lifters - £5,000

Labour costs - £22,000Others (straps, holiday costs, etc) - £2,000Reduction of accidents / near misses – cost

of trained operators, claims, increased insurance premiums

Estimated saving of £41,000 per year, over 3 years £123,000

Examples of theory Watch.htm