1. Welcome to LITTLEBOROUGH Site Overview 5S

2. Littleborough Location LITTLEBOROUGH HADDENHAM 3. Factory Plan View Whitelees Rd Freehold land New Mill St Stockton St 4. Factory Details

Whitelees Road Factory Footprint of 8000 m 2

Total Site area of 30000 m 2

Whitelees Road site produces all glass jars &

plastic container packs, plus Ultrakan products

24/5 shift pattern (24/6 during peak months)

200 Operations employees

• + seasonal requirements

Total Site area of 6000 m 2

New Mill Street Factory Footprint of 4000 m 2

New Mill Street site predominantlyproduces Dip Pots, Sachets and flexiblepacks (pouches, bag-in-box).

24/5 shift pattern (24/6 during high demandperiods)

90 Operations employees

• + seasonal requirements

5. Warehouse Details

Stockton Street Warehouse Footprint of 5000m 2

Total Site area of 12000m 2

Racking spaces for 3200 pallets

Stockton Street stores all packaging (glass jars,

plastic bottles, Ultracans, top-film, base web,

sachet laminate, boxes) and ambient

ingredients (powders, liquids)

24/5 shift pattern (24/6 during peak months)

14 Operations employees

6. SKU Count Tonnage1200T/wk Finished Goods SKUs 330 Packaging formats 35 Ingredient SKUs 320 Packaging SKUs 550 7. 5S At Littleborough 8.

Poor GMP Scores

Production & Process Areas in need of a Facelift

No Ownership of Equipment or Working Area

Poor Organisation of Space

Black Holes across the sites

Starting Point 9.

Project Brief

• Build a 5s Workshop

• Improve the Working Environment

• Facilitate in Organising Work Areas

Used an Existing Workshop Presentation

• Presentation Used by Nigel in the Past

• Presentation Branded to a McCormick Style by Facilitator

Starting Point 10.

Present 5s Overview to All Managers & Team Leaders

Pre-Brief The Area Leaders

Understand The Area/s to be Targeted

Send Out Invitations & 5s Overview Booklet

Group & Team Leader Participation in Workshops

Before The Workshop 11.

Pre-Training Information Booklet for Attendees Written & Produced In House

Before The Workshop 12.

Introduction / Overview of 5s

1 st5s Audit

Create A Vision

SORT

SET

SHINE

STANDARDISE

SUSTAIN

The Workshop 13.

1 stAudit

• Carry Out a Detailed Audit of The Area

• Complete a 5s Audit Sheet

Create A Vision

• Categorise The Possible Improvements To Be Made

• • • Current Conditions / Desired Conditions

• • • Making Operations Easier

• • • Action Plan

• • Safety

• • Quality

• • Equipment Maintenance

• • Efficiency Of Work

• • Inventory Levels

• • Information Sharing

The Workshop 14.

Sort

• Red Tag Technique

• Clear Area

• Red Tag Area

Engineers Red Tag Area - WLR

The Workshop 15.

BEFORE SORT

AFTER SORT

NMS Dry Prep

The Workshop 16.

SET

• Organise Area To Suit

• 30 Second Rule

• Mark & Label Areas

• • Equipment

• • Storage

• • WIP

• • Inventory

The Workshop 17.

SHINE

• Inspection

• Early Detection

• Create Shine Standard

The Workshop 18.

STANDARDISE

SUSTAIN

• Overview of the final 2s

The Workshop 19. The Workshop Each Certificate Personal to Recipient, Individually Signed & Copy Displayed 20.

Audits

Newsletters

5s Ideas

Action Plans

Post Workshop 21.

Audits Carried Out By Trained Audit Team

Post Workshop 22. Post Workshop 23. Post Workshop Comments 24.

Complete Standardise & Sustain Training

Planned Move of Equipment Area 5S

Next Steps 25. Equipment Moves 26.

Set a Budget for 5S Improvements

• Re-Organisation of Work Areas

• Improvement Ideas

Complete Engineering Areas 1 st

• If Engineers Buy In Improvements Will Be Easier To Drive

Plan Final 2S Sessions

• Commit to Completing The Workshop

What Would We Do Better? 27.

Awards & Recognition

• Best Audit Score

• Most Improved

• Stuck In The Mud

What Would We Do Better? 28.

Commit Resources and Plan

• All Shifts On The Workshop

• Planned Areas To Be Shutdown

• Involvement From All Levels

Own Facilitator

• Ownership of 5S Philosophy

• Consistent Approach

• Understanding Of Site

What Did We Do Right? 29.

Engineers On Every Workshop

• Break Down Barriers

• Able To Repair Problems Immediately

Momentum

• Complete Areas In Quick Succession

• Concentrate On The 1 st3S

• Stops Stagnation

• Everyone Can See The Commitment

What Did We Do Right? 30. Visual Management Planning The Workshops 31. Visual Management Branding The 5S Philosophy 32. Visual Management Branding The 5S Philosophy 33.

Quantity Control

• Control of Stock Levels

• Reminder to Re-Stock

Visual Management 34.

Use of Shadow Boards

• Controls Equipment

• Missing Equipment Identified

Visual Management 35. Improvements 36.

Rolled Out 5S in our South African Dry Plant (Midrand)

Blue Room

Rainbow Room

South Africa 37.

Engineering Area One Of The 1 stTo Embrace 5S

South Africa 38. South Africa 39.

Within 3 Months All Dry Plant Employees Completed a 5S Workshop

Interest From Other Sites In The U.S.A., Turkey & China

South Africa 40. FACTORY TOUR