LPE Industrial Academy 20162017 INDUSTRIAL PERFORMANCE AND LACTALIS

LPE Industrial Academy 2016/2017 INDUSTRIAL PERFORMANCE AND LACTALIS APPROACH MODULE 5: MONITORING – ACTING 1 Michel Jouanneaux 2016 -12 -7, 8, 9

2 Agenda day 2 LPE Industrial Academy 2016 - 2017 Monitoring Acting / Reacting 1 – basement : 5 S Acting / Reacting 2 – 1 st pillar FLOW : SMED and VSM ---------------------------------------- Plant visit – other departments Homework Assist the performance of individuals and teams Michel Jouanneaux REF S 2 -M 5 Industrial performance And Lactalis approach

LPE Industrial Academy 2016 - 2017 Monitoring 3 Management by objectives The right levers Gap analysis Objectives Reality is on g rin igh er Th er igh ta td ec isi na lys on ito Th Food Safety igh tm Th er igh tu Quality standard Th er sin go fd at a Social Human organization Production organization Build and organize indicators, KPI for decision Utilities & Energies Safety • • Data collection (manual, tool) Calculation & formula for indicators & Signification Data and indicators Monitoring Analysis and decision-making Assist the performance of individuals and teams Michel Jouanneaux REF S 2 -M 4 Industrial performance And Lactalis approach

LPE Industrial Academy 2016 - 2017 Monitoring 4 Monitor your operational data Budget building/Quality Standard Realty Accurate data collection Best practices Relevant monitoring indicators, KPI Decision making Organize action Best behaviors The best Operational Locking Which? Why? Who? When? How? Control the impact Assist the performance of individuals and teams Michel Jouanneaux REF S 2 -M 4 Industrial performance And Lactalis approach

LPE Industrial Academy 2016 - 2017 Monitoring A Full monitoring of your activity Reality Day 1 Controlling Day 30 Your guideline = Expected Budget + Quality Standard Accurate data collection Relevant monitoring indicators, KPI Decision making Organize action Control the impact You are the owner Daily management: what, why, how, where, who of your financial result • Reactivity • Better detection of industrial variability • Better knowledge on improvement points (savings, investments) Assist the performance of individuals and teams Michel Jouanneaux REF S 2 -M 4 Industrial performance And Lactalis approach

6 Agenda day 2 LPE Industrial Academy 2016 - 2017 Monitoring Acting / Reacting 1 – basement : 5 S Acting / Reacting 2 – 1 st pillar FLOW : SMED and VSM ---------------------------------------- Plant visit – other departments Homework Assist the performance of individuals and teams Michel Jouanneaux REF S 2 -M 5 Industrial performance And Lactalis approach

STRENGTHEN A SOLID PRODUCTION SYSTEM LPE Industrial Academy 2016 - 2017 7 1 – basement 5 S MACHINES IN ORDER – STANDARDIZE WORK Sor Set i t Shin n orde r Stan e d Sust ardiz ain e Assist the performance of individuals and teams Michel Jouanneaux KAIZEN APPROACH method 5 S Objectives : EFFICENCY BY ORDER AND CLEANLINESS REF S 2 -M 5 Industrial performance And Lactalis approach

STRENGTHEN A SOLID PRODUCTION SYSTEM LPE Industrial Academy 2016 - 2017 8 1 – basement 5 S BENEFITS Assist the performance of individuals and teams Michel Jouanneaux REF S 2 -M 5 Industrial performance And Lactalis approach

LPE Industrial Academy 2016 - 2017 STRENGTHEN A SOLID PRODUCTION SYSTEM 9 1 – basement 5 S ROLES AND BOUNDARIES COACH TEAM 5 S TOOL BOX Assist the performance of individuals and teams Michel Jouanneaux CAPTAIN BOUNDARIES SPONSOR REF S 2 -M 5 Industrial performance And Lactalis approach

STRENGTHEN A SOLID PRODUCTION SYSTEM LPE Industrial Academy 2016 - 2017 10 1 – basement 5 S VISUAL MANAGEMENT 0 S Assist the performance of individuals and teams Michel Jouanneaux REF S 2 -M 5 Industrial performance And Lactalis approach

STRENGTHEN A SOLID PRODUCTION SYSTEM LPE Industrial Academy 2016 - 2017 11 1 – basement 5 S 1 S SORT What: Sort and eliminate unnecessary items Why: To make a optimum use of space and time How: Define sorting rules - utility-frequency importance(significance) Useless items to throw away Undetermined items: Throw away? Move away? Put away? Creation of a buffer area Meeting to decide of the fate of the items/to decide whether to eliminate, move or put away the items Assist the performance of individuals and teams Michel Jouanneaux REF S 2 -M 5 Industrial performance And Lactalis approach

LPE Industrial Academy 2016 - 2017 STRENGTHEN A SOLID PRODUCTION SYSTEM 12 1 – basement 5 S 2 S SET IN ORDER What: Grant a storage location for each item Why: To increase the overall efficiency of the workplace How: A place for everything – everything at the right and visible place The locations have to show(specify) the stocks levels Label the storage area, the flow(circulation) zone Assist the performance of individuals and teams Michel Jouanneaux REF S 2 -M 5 Industrial performance And Lactalis approach

STRENGTHEN A SOLID PRODUCTION SYSTEM LPE Industrial Academy 2016 - 2017 13 1 – basement 5 S 3 S SHINE What: Create procedures of everyday storage and cleaning Why: Improve working environment for more safety, quality and efficiency How: Everything getting dirty every day is cleaned every day Settle the tiding up frequency and cleaning The tools and equipment of cleaning have to be set as close as possible to the workstation Share the tasks inside the team and post the rules Assist the performance of individuals and teams Michel Jouanneaux REF S 2 -M 5 Industrial performance And Lactalis approach

STRENGTHEN A SOLID PRODUCTION SYSTEM LPE Industrial Academy 2016 - 2017 14 1 – basement 5 S 4 S STANDARDIZE What: Settle a collective rule to maintain a tidy and clean workplace Why: The standardization is a reference and a sound base of progress How: Standard is a visual reference which allow the collective rules and lows A standard gather all the 3 first rules in order with the 3 S (sort, set in order, shine) Standard need collective acceptance to be the low witch enforce rigor and compliance Sum of standards are combined to an audit of the zone to check the ratio of conformity Assist the performance of individuals and teams Michel Jouanneaux REF S 2 -M 5 Industrial performance And Lactalis approach

STRENGTHEN A SOLID PRODUCTION SYSTEM LPE Industrial Academy 2016 - 2017 15 1 – basement 5 S 5 S SUSTAIN What: Perform compliance target and keep improving Why: Maintain the dynamics of the team to improve its performance How: results of audit, review of project, evaluation of the results Consider the evolutions of the environment Record the use of 5 S, keep new ideas In line with other aspect of the production system In a continuous improvement Assist the performance of individuals and teams Michel Jouanneaux REF S 2 -M 5 Industrial performance And Lactalis approach

STRENGTHEN A SOLID PRODUCTION SYSTEM LPE Industrial Academy 2016 - 2017 16 1 – basement 5 S INITIAL SITUATION Assist the performance of individuals and teams Michel Jouanneaux REF S 2 -M 5 Industrial performance And Lactalis approach

STRENGTHEN A SOLID PRODUCTION SYSTEM LPE Industrial Academy 2016 - 2017 17 1 – basement 5 S ACTION PLAN Assist the performance of individuals and teams Michel Jouanneaux REF S 2 -M 5 Industrial performance And Lactalis approach

STRENGTHEN A SOLID PRODUCTION SYSTEM LPE Industrial Academy 2016 - 2017 18 1 – basement 5 S STANDARDS AND AUDIT Assist the performance of individuals and teams Michel Jouanneaux REF S 2 -M 5 Industrial performance And Lactalis approach

STRENGTHEN A SOLID PRODUCTION SYSTEM LPE Industrial Academy 2016 - 2017 19 1 – basement 5 S Initial situation • • Analyse and gaps management • • • Audit result Annual revue Proposal from employees Action plan Pictures ‘before’ Y OM N O T AU Results under control • • Display Standards Regular Audits Assist the performance of individuals and teams Michel Jouanneaux Set up action plans • • • Sort Set in order Shine REF S 2 -M 4 Industrial performance And Lactalis approach

LPE Industrial Academy 2016 - 2017 STRENGTHEN A SOLID PRODUCTION SYSTEM 20 1 – basement 5 S 5 S INTEGRATION 5 S EXCELLENCE LEVEL Order and cleanliness Continuous improvement : Further status SHARE AND SUCCES Check : • Standard • Audit Targeted status After 5 S project • Audit in autonomy Analyze : • Results Display doing : • Sort • Set in order • Shine • Action plan • Solving - sourcing • Initial situation • Target • Action plan HAZARD • Non fulfilment of audit • Regression Initial status Long term Short term 0 S 1 S – 2 S – 3 S COACHING COACH TEAM MANAGEMENT 4 S 5 S AUTONOMY Methodological warranter Lead step by step initial status Targetting Analyse, action plan and implementation Realise audit and corresponding analyses Ensure the observance of the rules Implement solutions with simplicity – catch opportunities Ask for means and resources Launch the project Allocate means and ressources Stimulate autonomy Follow the results – ask for the reports Support improvement Rôles / players In 5 S project Assist the performance of individuals and teams Michel Jouanneaux REF S 2 -M 4 Industrial performance And Lactalis approach

STRENGTHEN THE STRUCTURE –METHODS AND TOOLS LPE Industrial Academy 2016 - 2017 21 Production system and OEE effects : 5 S 4 – SOLID ROOF INDICATORS Highest quality, lower cost, shortest lead time 2 - SOLID 1 ST PILLAR FLOW MANAGEMENT - TAKT TIME - PULL SYSTEM - CHANGE VSM SMED IMPLICATION IMPROVEMENT STANDARDS AND BEST PRACTICES TROUBLES SHOOTING TECHNICAL MANAGEMENT - 3 - SOLID PILLAR 2 ND CURATIVE M PREVENTIVE M IMPROVING M DRIVING AND ADJUSTMENTS TPM slowdown 1 SOLID BASEMENT MACHINES IN ORDER – STANDARDIZE WORK – 5 S 5 – STRONG PEOPLE Assist the performance of individuals and teams Michel Jouanneaux REF S 2 -M 4 Industrial performance And Lactalis approach

22 Agenda day 2 LPE Industrial Academy 2016 - 2017 Monitoring Acting / Reacting 1 – basement : 5 S Acting / Reacting 2 – 1 st pillar FLOW : SMED and VSM ---------------------------------------- Plant visit – other departments Homework Assist the performance of individuals and teams Michel Jouanneaux REF S 2 -M 5 Industrial performance And Lactalis approach

STRENGTHEN A SOLID PRODUCTION SYSTEM LPE Industrial Academy 2016 - 2017 23 2 – 1 ST PILLAR – FLOW / JIT BETTER ORGANISATION – PLANNING - CHANGE BETTER FLOW APPROACH JIT (VSM + SMED) Objectives : EFFICENCY BY STREAMLINE AND EFFICIENCY Assist the performance of individuals and teams Michel Jouanneaux REF S 2 -M 4 Industrial performance And Lactalis approach

STRENGTHEN A SOLID PRODUCTION SYSTEM LPE Industrial Academy 2016 - 2017 24 2 – 1 ST PILLAR - FLOW MAKE PROCESS MORE FLEXIBLE WITH Just In Time VSM : is a methodology aimed primarily at reducing wastes in the flow times SMED: is one of the many methods for reducing waste in an manufacturing process (change times) Assist the performance of individuals and teams Michel Jouanneaux REF S 2 -M 4 Industrial performance And Lactalis approach

LPE Industrial Academy 2016 - 2017 STRENGTHEN A SOLID PRODUCTION SYSTEM 25 2 – 1 ST PILLAR - VSM value stream mapping 8 h 5 golden rules Assist the performance of individuals and teams Michel Jouanneaux 4 h Streamline Eliminate intermediate stock Reduce waiting time Eliminate bottleneck Pull rather than push REF S 2 -M 4 Industrial performance And Lactalis approach

LPE Industrial Academy 2016 - 2017 STRENGTHEN A SOLID PRODUCTION SYSTEM 26 2 – 1 ST PILLAR - VSM Use symbols to represent the existing situation Key to symbols used in documentation Map the process Analytically graphically Assist the performance of individuals and teams Michel Jouanneaux REF S 2 -M 4 Industrial performance And Lactalis approach

LPE Industrial Academy 2016 - 2017 STRENGTHEN A SOLID PRODUCTION SYSTEM 27 2 – 1 ST PILLAR - FLOW Design action plan to reach targeted organisation Key to symbols used in documentation Analyze wastes and act Reducing time, added value Eliminate Adjustments Streamline Reduce time Useless tasks Stocks Over products Eliminate Useless or complex movements Assist the performance of individuals and teams Michel Jouanneaux Waiting Handling REF S 2 -M 4 Industrial performance And Lactalis approach

STRENGTHEN THE STRUCTURE –METHODS AND TOOLS LPE Industrial Academy 2016 - 2017 28 Production system and OEE effects : VSM 4 – SOLID ROOF INDICATORS Highest quality, lower cost, shortest lead time 2 - SOLID 1 ST PILLAR FLOW MANAGEMENT - TAKT TIME - PULL SYSTEM - CHANGE VSM SMED IMPLICATION IMPROVEMENT STANDARDS AND BEST PRACTICES TROUBLES SHOOTING TECHNICAL MANAGEMENT - 3 - SOLID PILLAR 2 ND CURATIVE M PREVENTIVE M IMPROVING M DRIVING AND ADJUSTMENTS TPM slowdown 1 SOLID BASEMENT MACHINES IN ORDER – STANDARDIZE WORK – 5 S 5 – STRONG PEOPLE Assist the performance of individuals and teams Michel Jouanneaux REF S 2 -M 4 Industrial performance And Lactalis approach

STRENGTHEN A SOLID PRODUCTION SYSTEM LPE Industrial Academy 2016 - 2017 29 2 – 1 ST PILLAR - SMED : Single-Minute Exchange of Die Step 1 : record Step 4 : convert internal to external Assist the performance of individuals and teams Michel Jouanneaux Step 2 : analyse and process data Step 5 : simplify Streamline and check Step 3 : separate internal and external Step 6 : standardize communique / trained REF S 2 -M 4 Industrial performance And Lactalis approach

STRENGTHEN A SOLID PRODUCTION SYSTEM LPE Industrial Academy 2016 - 2017 30 2 – 1 ST PILLAR - SMED Assist the performance of individuals and teams Michel Jouanneaux REF S 2 -M 4 Industrial performance And Lactalis approach

STRENGTHEN A SOLID PRODUCTION SYSTEM LPE Industrial Academy 2016 - 2017 31 2 – 1 ST PILLAR - SMED Assist the performance of individuals and teams Michel Jouanneaux REF S 2 -M 4 Industrial performance And Lactalis approach

STRENGTHEN A SOLID PRODUCTION SYSTEM LPE Industrial Academy 2016 - 2017 32 2 – 1 ST PILLAR - SMED Assist the performance of individuals and teams Michel Jouanneaux REF S 2 -M 4 Industrial performance And Lactalis approach

STRENGTHEN A SOLID PRODUCTION SYSTEM LPE Industrial Academy 2016 - 2017 33 2 – 1 ST PILLAR - SMED Assist the performance of individuals and teams Michel Jouanneaux REF S 2 -M 4 Industrial performance And Lactalis approach

STRENGTHEN THE STRUCTURE –METHODS AND TOOLS LPE Industrial Academy 2016 - 2017 34 Production system and OEE effects : SMED 4 – SOLID ROOF INDICATORS Highest quality, lower cost, shortest lead time 2 - SOLID 1 ST PILLAR FLOW MANAGEMENT - TAKT TIME - PULL SYSTEM - CHANGE VSM SMED IMPLICATION IMPROVEMENT STANDARDS AND BEST PRACTICES TROUBLES SHOOTING TECHNICAL MANAGEMENT - 3 - SOLID PILLAR 2 ND CURATIVE M PREVENTIVE M IMPROVING M DRIVING AND ADJUSTMENTS TPM slowdown 1 SOLID BASEMENT MACHINES IN ORDER – STANDARDIZE WORK – 5 S 5 – STRONG PEOPLE Assist the performance of individuals and teams Michel Jouanneaux REF S 2 -M 4 Industrial performance And Lactalis approach