Problem Description The process of saucemix delivery is high in Non-Value Adding (NVA) activity (98%). The process highlights long distances travelled (3,350 miles) resulting in potential high risk accidents and high labour content of approximately £22,032 PA over 3 shifts.

What does good look like? A process that delivers the sauce mix to the machine autonomously that is safe and easy to clean being quality friendly. This will result in zero accidents, zero downtime and savings in excess of £123,000 over 3 years.

Team Kevin BrownMark WalshAmy LangridgeDavid Stephens

Measurables MeasurementCurrentActual Cost£41,000 PA£123,000 savings over three years for 3 lines QualityRelies on Two Eye Check Manual input into system Transport & Load issues Two tier delivery system to avoid cross contamination remove unnecessary wastage Safety14 near misses and 1 serious safety breach resulting in employee dismissal Zero accidents and near misses for this task ProductivityTime 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 369 MEDIUM 246 HIGH 123 LOWMEDIUMHIGH COST BENEFIT

Critical success factors Quality acceptance Safety acceptance Ergonomically compliant Buy in from works director Workforce acceptance Union agreement Maintenance engineering Environmental impact Cost saving focus (Labour, Waste & Materials)

Action Plan ItemActionResponsibility Flow processMap out flow processCompleted by team Equipment Cost out and spec delivery system Budget quote received based on one line CommunicationConsult with stakeholders Review Present findings to management DecisionFinalise decision process

Progress Chart

COSTS 156metres travelled studied on Line 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 shift 7.1 mins x 8 = 56.8 mins per shift Cost per 24 hour period 2,496 x 3 = 7,488 metres per shift 56.8 mins x 3 = mins (2.84 hours per 24 hour shift) Cost for 3 lines for 24 hour period 7,488 metres x 3 = 22,464 metres 2.84 hours x 3 = 8.52 hours Costs for 3 lines for 5 day week 22, 464 x 5 = 112, 320 metres 8.52 hours x 5 = 42.6 hours per week Annual cost 112, 320 metres x 48 = 5, 391, 360 metres or 3,350 miles 42.6 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 Savings Leasing for 4 IBC lifters – £10,000 Training for lifters - £2,000 Maintenance of lifters - £5,000 Labour costs - £22,000 Others (straps, holiday costs, etc) - £2,000 Reduction 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