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SUPPLY CHAIN LIVE SUPERIOR SERVICE, DELIVER SUSTAINABLE, PROFITABLE GROWTH SEP 2013 Larry Gibson – Manufacturing Director COVINGTON.

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Presentation on theme: "SUPPLY CHAIN LIVE SUPERIOR SERVICE, DELIVER SUSTAINABLE, PROFITABLE GROWTH SEP 2013 Larry Gibson – Manufacturing Director COVINGTON."— Presentation transcript:

1 SUPPLY CHAIN LIVE SUPERIOR SERVICE, DELIVER SUSTAINABLE, PROFITABLE GROWTH SEP 2013 Larry Gibson – Manufacturing Director COVINGTON

2 FACTORY TIMELINE  Slim Fast Company acquired by Unilever  High strength waste treatment facility completed  1 st Super-shots line in North America installed and operational  Project Yorktown (Slim- Fast Restructuring)  Project Lexington (Super Shots Exit) 0003  Project Odyssey (Ice Cream). Engineering starts.  Slim Fast RTD production ceases (June 30 th )  Ice Cream Manufacturing begins in Space Saver (PIC) on Aug 29 th  1st Stickless extruded Line (Klondike) starts on Oct 26 th with Reese’s  Moulded Line starts on Dec 15 th with Mighty Minis production  Land O’ lakes (copacker of Slim-Fast ) completes construction and inititates start-up. Building size is approx. 400,000 sq. ft.  Slim-Fast Foods Company assumes ownership of Covington  R&D Pilot Plant Start-up  280,000 sq. ft. expansion (Distribution Center)  Two additional packaging lines installed (doubling capacity).  Processing & canning expanded by 50%

3 LIVE SUPERIOR SERVICE, DELIVER SUSTAINABLE, PROFITABLE GROWTH THE JOURNEY TO ICE CREAM Infant Toddler Adult Child Teen

4 LIVE SUPERIOR SERVICE, DELIVER SUSTAINABLE, PROFITABLE GROWTH Factory Passport Building Area: 808,000 sq ft (75,000 sq mt) Land Area: 3,556,000 sq ft (330,000 sq mt) PIC - Packaged Ice Cream (Breyers) Stickless Extruded (Klondike) Molded (Popsicle / Good Humor) 2013 Volumes: 95,016 Liton PIC: 54,991 Liton (51 SKU’s) Klondike: 21,655 Liton (4 SKU’s) Molded: 18,370 Liton (12 SKU’s) Production Lines: 14 (pack capacity 206,000) - SS-1: PIC - speed 70cpm - SS-2: PIC - speed 70cpm - SS-3: PIC - speed 70cpm - SS-4: PIC – speed 70cpm - KL-1: Klondike (stickless extruded) – speed 600bpm - KL-2: Klondike (stickless extruded) – speed 600bpm - KL-3: Klondike (stickless extruded) – speed 600bpm - Gram 1: Molded – speed 140 pcs/min - Gram 2: Molded – speed 455 pcs/min - Gram 3: Molded – speed 455 pcs/min - Gram 4: Molded – speed 280 pcs/min - Gram 5: Molded – speed 624pcs/min - Gram 6: Molded – speed 520 pcs/min - Gram 7: Molded – speed 624 pcs/min Mix Room: 2 - PIC Mix Room capacity: 6,000gph* (2 HTST*) - Novelty Mix Room capacity: 6,000gph* (2 HTST) Refrigeration: - Current Refrigeration Load: 5,875 ton - Current Ammonia Load: 125,000 lbs Cold Storage: - Fully Automated – 4,000 pallet positions 2013 Budget: €63.7M at $1,2831: €1.00 STAFFING (Jan/13) 13 Managers 22 Supervisors (WL1) 462 Hourly Employees 178 Temporary Workforce

5 LIVE SUPERIOR SERVICE, DELIVER SUSTAINABLE, PROFITABLE GROWTH OVERVIEW What does a modern foods factory look like? Automation Robotics HMI What does this mean for operators? Math/Analytical Skill/Reading comprehension What Unilever is doing to continuously improve our workforce! OJT BLITZ IRT for All (Unilever University) Advanced Training

6 LIVE SUPERIOR SERVICE, DELIVER SUSTAINABLE, PROFITABLE GROWTH TEAM WORK

7 LIVE SUPERIOR SERVICE, DELIVER SUSTAINABLE, PROFITABLE GROWTH GRAM Consumer Safety, Teammate Safety & Quality Operators Performing a Changeover Gram Equipment Robotic packaging Automated Case packing

8 LIVE SUPERIOR SERVICE, DELIVER SUSTAINABLE, PROFITABLE GROWTH SPACE SAVER Consumer Safety, Teammate Safety & Quality Graphical Equipment representation Breyers Modern packaging equipment Computer Touch Screen Online statistical controls Automated Downtime analysis

9 LIVE SUPERIOR SERVICE, DELIVER SUSTAINABLE, PROFITABLE GROWTH KLONDIKE Consumer Safety, Teammate Safety & Quality Delicious products! Klondike Robots Modern Quality assurance equipment High volume production Ice Cream Production

10 LIVE SUPERIOR SERVICE, DELIVER SUSTAINABLE, PROFITABLE GROWTH MIX Consumer Safety, Teammate Safety & Quality In department Mixing Calculations Batching High Tech HTST

11 SUPPLY CHAIN LIVE SUPERIOR SERVICE, DELIVER SUSTAINABLE, PROFITABLE GROWTH B ASIC L EARNING I NTENSIVE T RAINING Z ONE TRAINING GUIDES UNILEVER COVINGTON, TN

12 LIVE SUPERIOR SERVICE, DELIVER SUSTAINABLE, PROFITABLE GROWTH COMPETENCY CHECK GUIDE USED TO VALIDATE OPERATOR IS FULLY COMPETENT TO RUN THE TECHNICAL ASPECTS OF THE EQUIPMENT.

13 LIVE SUPERIOR SERVICE, DELIVER SUSTAINABLE, PROFITABLE GROWTH SKILLS TRAINING MATRIX Klondike Warehous e Space Saver Mix

14 LIVE SUPERIOR SERVICE, DELIVER SUSTAINABLE, PROFITABLE GROWTH BUT ALL THIS IS NOT ENOUGH!

15 LIVE SUPERIOR SERVICE, DELIVER SUSTAINABLE, PROFITABLE GROWTH COVINGTON PEOPLE DEVELOPMENT Mission: Enable factory workers to learn and grow their contributions and rewards by building skills that allow them to meet our consumer and company needs Deliverables: Skilled/ Flexible workforce Highly Engaged workforce Environment where “Variable Pay” is the Motivation Competitive Advantage: Technical Business partners are running the business day to day. Employees are the investment and deliver stakeholder returns. The Vision of the Site and Company is internalized and demonstrated

16 Prospective Candidates Soft Skills Teamwork Math Reading Locating Information Prospective Candidates Soft Skills Teamwork Math Reading Locating Information OJT Train- the-Trainer Basic Machines Validated Pre and Post tests CRC Mechanical Aptitude OJT Train- the-Trainer Basic Machines Validated Pre and Post tests CRC Mechanical Aptitude IRT Maintenance Shop Math Operator Core Fundamentals Pneumatics & Hydraulics Electrical Components Pump Basics Valve Operation Failure Analysis Gearbox & Bearing Advanced Pneumatic Advanced Hydraulic Advanced Electrical Pump Maintenance Intro to Welding Machine Shop Practices Machine Adjustments Ladder Logic PLC Advanced Electrical Maintenance Shop Math Operator Core Fundamentals Pneumatics & Hydraulics Electrical Components Pump Basics Valve Operation Failure Analysis Gearbox & Bearing Advanced Pneumatic Advanced Hydraulic Advanced Electrical Pump Maintenance Intro to Welding Machine Shop Practices Machine Adjustments Ladder Logic PLC Advanced Electrical Operator Blueprint Reading Measurement Hand Tools Mechanical Components I Bearings & Lubrication Mechanical Components II Machine Adjustment Operator Blueprint Reading Measurement Hand Tools Mechanical Components I Bearings & Lubrication Mechanical Components II Machine Adjustment MECHANICAL Workplace Safety Preventive Maintenance Quality Control & SPC Hydraulic/Pneumatic Fluid Power Distribution Piping and Pneumatic Mechanical Installation Basic Pneumatic Controls Basic Hydraulic Controls Intermediate Pneumatic Intermediate Hydraulic Power Transmission Systems Advanced Mechanical MECHANICAL Workplace Safety Preventive Maintenance Quality Control & SPC Hydraulic/Pneumatic Fluid Power Distribution Piping and Pneumatic Mechanical Installation Basic Pneumatic Controls Basic Hydraulic Controls Intermediate Pneumatic Intermediate Hydraulic Power Transmission Systems Advanced Mechanical MAINTENANCE PROGRESSION Electrical MechAniaLMechAniaL MechAniaLMechAniaL ConTrolsConTrols ConTrolsConTrols OROR Maintenance Technician I Skill Assessment Test Maintenance Technician II Skill Assessment Test Maintenance Technician III Skill Assessment Test AAS Degree Advanced Industrial Integrated Technology AAS Degree Advanced Industrial Integrated Technology Certificate Programs Certificate Programs Certificate Programs Certificate Programs Apprenticeship Program ELECTRICAL Workplace Safety Preventive Maintenance Quality Control & SPC Basic Electricity Power Development Electrical Power Distribution Electrical Installation Basic Electrical Controls Intermediate Electrical Controls ELECTRICAL Workplace Safety Preventive Maintenance Quality Control & SPC Basic Electricity Power Development Electrical Power Distribution Electrical Installation Basic Electrical Controls Intermediate Electrical Controls CONTROLS Workplace Safety Preventive Maintenance Quality Control & SPC Principles of Instrumentation Integrated Process Control Integrated Process Management Programmable Logic Controls CONTROLS Workplace Safety Preventive Maintenance Quality Control & SPC Principles of Instrumentation Integrated Process Control Integrated Process Management Programmable Logic Controls Controls ConTrolsConTrols ConTrolsConTrols Mechanical MechAniaLMechAniaL MechAniaLMechAniaL CORE

17 LIVE SUPERIOR SERVICE, DELIVER SUSTAINABLE, PROFITABLE GROWTH SO WE LEVERAGE OUR PARTNERSHIP WITH SOUTHWEST! UNILEVER UNIVERSITY SPONSORED BY SOUTHWEST TENNESSEE COMMUNITY COLLEGE


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