Transcript Slide 1

COVINGTON
SUPPLY CHAIN
Larry Gibson – Manufacturing
Director
SEP 2013
LIVE SUPERIOR SERVICE,
DELIVER SUSTAINABLE,
PROFITABLE GROWTH
FACTORY TIMELINE
1996 - 2000
96
98
2000 - 2009
00
 Slim Fast Company
acquired by Unilever
03
 High strength waste
treatment facility completed
 Slim-Fast Foods
Company assumes
ownership of Covington
07
 1st Super-shots line in
North America installed and
operational
 R&D Pilot Plant Start-up
09
 Project Yorktown
(Slim-Fast Restructuring)
 Land O’ lakes (copacker
of Slim-Fast ) completes
construction and inititates
start-up. Building size is
approx. 400,000 sq. ft.
 280,000 sq. ft. expansion
(Distribution Center)
99
 Two additional packaging
lines installed (doubling
capacity).
00
 Processing & canning
expanded by 50%
 Project Lexington (Super
Shots Exit)
2010 - 2011
10
 Project Odyssey
(Ice Cream).
Engineering starts.
11
 Slim Fast RTD production
ceases (June 30th)
 Ice Cream Manufacturing
begins in Space Saver (PIC)
on Aug 29th
 1st Stickless extruded Line
(Klondike) starts on Oct 26th
with Reese’s
 Moulded Line starts on Dec
15th with Mighty Minis
production
THE
JOURNEY TO
ICE CREAM
Adult
Teen
Child
Toddler
Infant
LIVE SUPERIOR SERVICE,
DELIVER SUSTAINABLE,
PROFITABLE GROWTH
Factory Passport
Production Lines: 14 (pack capacity 206,000)
Building Area:
Land Area: 3,556,000
808,000
sq ft (330,000 sq mt)
sq ft (75,000 sq mt)
-
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 Volumes: 95,016 Liton
PIC - Packaged Ice
Cream
(Breyers)
Stickless Extruded
(Klondike)
Molded
(Popsicle / Good Humor)
STAFFING (Jan/13)
13 Managers
22 Supervisors (WL1)
462 Hourly Employees
178 Temporary Workforce
PIC: 54,991 Liton (51 SKU’s)
Klondike: 21,655 Liton (4 SKU’s)
Molded: 18,370 Liton (12 SKU’s)
2013 Budget: €63.7M at $1,2831: €1.00
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)
LIVE SUPERIOR SERVICE,
DELIVER SUSTAINABLE,
Advanced Training
PROFITABLE GROWTH
TEAM WORK
LIVE SUPERIOR SERVICE,
DELIVER SUSTAINABLE,
PROFITABLE GROWTH
Gram Equipment
GRAM
Automated Case packing
Robotic
packaging
Operators Performing a
Changeover
LIVE SUPERIOR SERVICE,
DELIVER SUSTAINABLE,
PROFITABLE GROWTH
Consumer Safety, Teammate Safety & Quality
SPACE SAVER
Breyers Modern packaging
equipment
Graphical Equipment representation
Automated
Downtime
analysis
Computer Touch Screen
Online statistical controls
LIVE SUPERIOR SERVICE,
DELIVER SUSTAINABLE,
PROFITABLE GROWTH
Consumer Safety, Teammate Safety & Quality
Delicious
products!
KLONDIKE
Modern Quality assurance
equipment
High volume
production
Klondike
Robots
Ice Cream Production
LIVE SUPERIOR SERVICE,
DELIVER SUSTAINABLE,
PROFITABLE GROWTH
Consumer Safety, Teammate Safety & Quality
High Tech HTST
MIX
In department Mixing
Calculations
Batching
LIVE SUPERIOR SERVICE,
DELIVER SUSTAINABLE,
PROFITABLE GROWTH
Consumer Safety, Teammate Safety & Quality
SUPPLY CHAIN
B ASIC
L EARNING
I NTENSIVE
T RAINING
Z ONE
TRAINING GUIDES
UNILEVER
COVINGTON, TN
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.
LIVE SUPERIOR SERVICE,
DELIVER SUSTAINABLE,
PROFITABLE GROWTH
SKILLS
TRAINING
MATRIX
Klondike
Warehous
e
Space Saver
Mix
LIVE SUPERIOR SERVICE,
DELIVER SUSTAINABLE,
PROFITABLE GROWTH
BUT ALL THIS IS NOT
ENOUGH!
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
LIVE SUPERIOR SERVICE,
DELIVER SUSTAINABLE,
PROFITABLE GROWTH
IRT
CORE
Operator
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Prospective
Candidates
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Soft Skills
Teamwork
Math
Reading
Locating
Information
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OJT Trainthe-Trainer
Basic
Machines
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Validated Pre
and Post tests
• CRC
• Mechanical
Aptitude
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Blueprint Reading
Measurement
Hand Tools
Mechanical
Components I
Bearings &
Lubrication
Mechanical
Components II
Machine
Adjustment
AAS Degree
Advanced
Industrial
Integrated
Technology
MAINTENANCE PROGRESSION
Maintenance Technician III Skill Assessment Test
Controls
Certificate
Programs
M
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c
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A
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a
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Maintenance
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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
Certificate
Programs
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O
R
C
o
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T
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o
l
s
Electrical
Maintenance Technician I Skill Assessment Test
MECHANICAL
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Mechanical
Maintenance Technician II Skill Assessment Test
Apprenticeship
Program
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M
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C
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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
CONTROLS
ELECTRICAL
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Workplace Safety
Preventive Maintenance
Quality Control & SPC
Basic Electricity
Power Development
Electrical Power
Distribution
Electrical Installation
Basic Electrical
Controls
Intermediate Electrical
Controls
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Workplace Safety
Preventive
Maintenance
Quality Control &
SPC
Principles of
Instrumentation
Integrated Process
Control
Integrated Process
Management
Programmable Logic
Controls
SO WE LEVERAGE OUR PARTNERSHIP
WITH SOUTHWEST!
UNILEVER UNIVERSITY
SPONSORED BY
SOUTHWEST
TENNESSEE COMMUNITY
COLLEGE
LIVE SUPERIOR SERVICE,
DELIVER SUSTAINABLE,
PROFITABLE GROWTH