WAN-IFRA BERLIN 2013 NEWSPRINTERS CONTINUOUS IMPROVEMENT SYSTEM
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- Brent Brown
- 5 years ago
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1 WAN-IFRA BERLIN 2013 NEWSPRINTERS CONTINUOUS IMPROVEMENT SYSTEM
2 Newsprinters
3 What we do
4 NEWSPRINTERS LEAN MANUFACTURING SERVICES How we do it Raw Materials (Paper, Ink, Font and Plates) Logistics Post Press - Packaging Preparation Plate Making Printing Presses Paper Handling
5 Newsprinters Vision
6 INTRODUCTION TO LEAN
7 Lean Manufacturing W. Edwards Deming told the world that Management must change fundamentally, transform its attitude towards the worker, understand variation and focus on the system. (Deming W. E., 1986) Taiichi Ohno All we are doing is looking at the time line, from the moment the customer gives us an order to the point when we collect cash. And we are reducing that time line by removing the non-value added waste (Ohno T, 1988) James Womack and Daniel Jones brought the term Lean to the world s attention and sent a wake-up call to all organisations and suggested that the Toyota Production System was the new way for manufacturing excellence. (Womack, Jones, & Roos, 1990)
8 Lean Manufacturing Strategy for removing all non value added processes and activities
9 Lean Manufacturing Tools 7 Wastes & Hidden Factory Workplace Organisation - 5S Visual Standards & Audits Visual Controls & Visual Factory PDCA KANBAN SMED Process Mapping Value Stream Mapping Asset & Activity Criticality Assessment JIT JIDOKA Pokeyoke Problem Solving RCA FMEA Maintenance Best Practices RCM TPM Kaizen Cycle Some Lean Tools
10 TOTAL PROCTUCTIVE MANUFACTURING
11 TPM Newsprinters Holistic System 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
12 Core Principle Remove all Waste
13 Core Principle Activity and Asset Reliability 100% Operating Condition P Failure starts to occur Ultrasonic Vibration Oil Condition Based Maintenance Thermal Sight Noise Heat Smell On-Condition Based Maintenance Time (time periods for illustrative purposes only) - George Donaldson 2005 F Failure has occurred
14 WORKPLACE ORGANISATION
15 What is 5S? 5S is the most fundamental improvement activity for any business. In 1924 Henry Ford wrote Good work requires good tools in a good organised environment
16 NEWSPRINTERS LEAN MANUFACTURING SERVICES Pilot - Ink Room
17 5S So you can see the waste
18 Before 5S
19 NEWSPRINTERS LEAN MANUFACTURING SERVICES Sort & Shine Days
20 NEWSPRINTERS LEAN MANUFACTURING SERVICES Set In Order Days
21 5S Make it obvious
22 NEWSPRINTERS LEAN MANUFACTURING SERVICES 5S Staff Set Standards
23 NEWSPRINTERS LEAN MANUFACTURING SERVICES 5S Across the Group
24 PDCA System ACT: If results are good develop standards. If results are bad revise and redo PDCA PLAN: Define a problem or opportunity Develop an implementation plan CHECK: Analyse information Monitor trends Compare results DO: Implement corrective action Document procedures & observations 24
25 Systems Where Everybody Audits Staff and Frontline Managers - Daily Managers - Weekly Senior Managers Monthly Executive Directors - Quarterly
26 NEWSPRINTERS LEAN MANUFACTURING SERVICES Eurocentral Knowsley Broxbourne
27 KANBAN
28 NEWSPRINTERS LEAN MANUFACTURING SERVICES BEFORE
29 NEWSPRINTERS LEAN MANUFACTURING SERVICES AFTER
30 Kanban 30
31 SMED
32 Pit Stop
33 Knowsley
34 OPERATIONAL EXCELLENCE
35 Eurocentral
36 NEWSPRINTERS ACCOMPLISHMENTS
37 It s not a Toolset it s a Mindset!
38 NEWSPRINTERS LEAN MANUFACTURING SERVICES Lean Manufacturer of the Year
39 Printer & Environmental Company of the Year
40 Printer of the Year -2013
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