6S Implementation Project at Synlait Farms Senior Leadership Team - - PowerPoint PPT Presentation

InSynC Programme - 6S Implementation Project at Synlait Farms

Senior Leadership Team on a Field Trip to North Island Feb 2011

SLT and PIT team training from February - May 2012

InSynC Launch on 23rd February 2012

Training days for individual farm teams

• 1. Introduction to InSynC
• 2. Waste education
• 3. Message of empowerment to identify 7 wastes and consider

removing waste to make work ‘easier, better, faster and safer’.

Identifying Wastes - 6S Plan in action

: Waiting for instruction for next job : Not taking all required tools for doing a job Storing the adequate amount : Searching for things : data and surplus grass : Not correct first time repetition or correction

• f a process

: plant wash procedure

: An 8th waste is the wasted potential of people

31 24 9 25

43

9 19

5 10 15 20 25 30 35 40 45 50

Motion and Searching Waiting Inventory Transport Defects Over production Inadequate processes

Waste Analysis

(Waste Hunt completed by each individual)

Organising the work place is the key

Defining 6S Areas and 6S Audit Training

Dairy Shed 6S Scores - 6S Plan in Action

We encourage and help teams to sustain or improve what they achieve!

When using the other InSynC tools, always consider where your action plan fits in the 6S circle.

Value Stream Map is an effective starting point

1.Engaging Our Teams

2.Developing Our Innovative Culture

Description Description

Time saving on searching, waiting and motion 30min/0.5hrs /day/employee Saved hours spent by an employee on average per year 124.5hrs Total # of staff at Synlait 80 Potential value of labour saving per annum (80*124.5*$21.14) = $210,000

3.Reduce waste and enhancing

• ur financial performance

Result of implementing 6S in dairy sheds

• 4. Adding Value for our Customers

Reduction in Somatic Cell Count has saved us $ 585,000/year

5.Taking Care of Our Environment and Ourselves

Before After

Promote Process Improvement Reward Results Involve Team Members Deliver Excellence Educate Recognition and PRIDE

6 S is an important part of the InSynC journey

Vision and Goals InSynC tools

Team Engagement Learning Innovation Empowerment

Top to bottom approach Change management Bottom to top approach Possibility and risk assessment Project methodology

6S

Process improvement & data integrity

InSynC projects for next 12 months

Sustaining :

• Keep organising 6S audits across all the dairy sheds. Continually improve 6S scores and
• sustain. Start implementing 6S across other areas of the farm as agreed.
• Complete the Milking Efficiency Management project.

Communication, recognition and reward :

• Deliver a once a month InSynC Show Day – All farm teams should have a turn at

hosting these events.

• Visit farms and help them during their weekly InSynC meetings.
• Once a month newsletter and weekly TV slides.
• Idea management – no cost or low cost ideas are considered first. Recognise those

team members coming up with ideas during show days and record number of ideas/team member/year.

• InSynC award to be awarded once a 3 months under agreed criteria.

Training

• 5 PIT team training sessions to be completed.

Take Home Message

Name of the Programme – InSynC - Duration - 2 years and 7 months Completed Project : Implementation of 6S at Synlait Farms – 14 sites Duration : 18 months (on going effort for sustaining) for 6S project – InSynC Results : Intangible

• Improved team engagement, empowerment, team spirit and development of a new

culture required for implementing lean principles.

• Improved health and safety awareness with new procedures established.
• Robust foundation for looking after our environment with the establishment of improved

procedures for disposing of rubbish and shining schedules.

• Happy customers as we improve product quality and quantity due to standardising our

procedures within the dairy shed and enhancing the dairy surrounds.

• Establishing a sense of urgency within the New Zealand dairy industry involving Dairy NZ

from the start and supporting them with our learnings.

Results : Tangible

• Increased number of innovative ideas for reducing wastes – 56 ideas were recognised and

shared.

• Total estimated time saved across all the farms valued at $210,000/year.
• Improved SCC has saved $585,000 /year

Thank you