Princes Limited
An Application of Autonomous Maintenance
Our History
Princes’ heritage dates back to 1880 when
it was established as a fish importing
business
in Liverpool, the city where our international
headquarters are still located today.
The iconic Princes brand was first established
in 1900 and is familiar to millions of
consumers
As a wholly-owned subsidiary of Mitsubishi
Corporation since 1989, Princes has
accelerated its development over the last two
decades by completing 22 mergers and
acquisitions that have added scale and
expertise to the business.
Chichester
Glasgow
Eden Valley
Manchester
Church Stretton
Cardiff
Long Sutton
Wisbech
Belvedere
Bradford
Princes Locations Netherlands
Princes Foods B.V.
Princes Tuna (Mauritius)
Mauritius x 2
Italy
Poland
Szamotuly
Princes Polska
Office Drink Site Food Site Oil Site
Erith
Liverpool Head Office
Foggia
Angri
France
Princes Foods B.V.
Princes France
opened Jan 2016
The Goal – “Make money now & in the future”…How…
The Goal
Novel by Eliyahu M. Goldratt and Jeff Cox
Princes
Practice
( Typical)
UK – Foods
Best Practice
*
Maintenance
Activity Type
Condition
Based
Maintenance
10% 25% Check to see if
failed
8% 33% Check to see if
failing
Periodic
Maintenance 78% 5%
Fixed time /
cycle
maintenance
- 2% 4% Re-design
Breakdown
Maintenance 2% 33%
Planned run to
failure – no
business
impact
100% 100%
Sources - The Lean Manufacturing Journal
- Onsite Insights
- AMIS Benchmarking data
Getting Started
We agreed on some principles…
The Five Fundamentals of Princes Asset Management
1. Increase Employee Involvement in Asset Care.
2. Stop Accelerated Deterioration.
3. Restore Basic Condition.
4. Move From Reactive to Proactive Maintenance.
5. Deliver New Equipment that can deliver Flawless Operation
From Day One with the lowest Life Cycle Cost
We Visualised our Journey to World Class Asset Management.
Reactive Proactive
Breakdown
Maintenance
Condition Based
Maintenance
Periodic
Maintenance
Supporting
Business
Improvement
Incorporating
Autonomous
Maintenance
90%
Performance
Efficiency
Zero
Breakdowns
Princes Current Position
Getting Started – Then we drew out a map of the whole
PMS system …
PMS Roadmap First Draft Approx. 2010
PMS Roadmap 2015
Then we prepared an PMS audit…….
Section Details Questions Section Score Zero’s
Theme 1 Management Information
11 1.0 – 1.11 Do we clearly understand what we should be doing?
Theme 2 Measurement
10 2.0 – 2.10 Do we know how to measure and track progress on our plans?
Theme 3 Man / Woman
11 3.0 - 3.11 Do we have the right skills and structures among our people to deliver on our plans?
Theme 4 Methods
11 4.0 - 4.11 Do we have standard work for our people to follow?
Theme 5 Machine
16 5.0 - 5.16 Do we have sufficient capacity and capability in our equipment?
Theme 6 Materials
3 6.0 - 6.3 Do we have the right quality and availability of materials to achieve our plans?
Theme 7
Enablers
3 7.0 -7.3 · Do we know how to manage change?
· Do we know where our real bottlenecks are?
· Can we think creatively about our business challenges now and in the future?
Development levels agreed…..
5 .1
AM/PrM deployment plan
Evidence –AM deployment
plan
None AM deployment plan is ad-
hoc
Within the MWBP Plan, a
basic stand alone plan for the
AM deployment has been
defined
Within the MWBP more
detailed plan for the AM Pillar
has been defined with some
linkages to other pillars e.g.
5S.
Within the site MWBP, a
detailed AM deployment plan
has been defined which
clearly illustrates the linkages
between AM and all related
activities in the 5S,
Professional Maintenance
pillars
5.2
AM Programme
Deployment
Evidence –AM deployment
plan
None AM Steps 1-3 only been
undertaken in pilot area(s)
AM Steps 1-3 only been
undertaken on AA,A and
Constraint machines
AM Steps 1-3 deployed in
over 50%, of the site
AM Steps 1-3 fully (100%)
deployed in all areas where
applicable
Ref Criteria 0 Points
Not Started
Level 1
1 point
Beginning
Level 2
2 points
Competent
Level 3
3 Points
Proficient
Level 4
4 Points
Expert
Level 5
Baselines & targets set………
5.1 AM / PrM Deployment Plan 3
5.2 AM Programme Deployment 1
5.3 AM Benefits - Impact on Loss Tree 1
5.4 AM Activity Boards 1
5.5 AM Step 1 Initial Clean - Tools, Material & PPE 4
5.6 AM Step 2 Identification of SOC & HTA 1
5.7 AM Step 3 Development of Lubrication Standards 1
5.8 AM Step 3 Development of Provisional CIL Standards 1
5.9 AM Support - Leader Training 3
5.10 AM Support - Leader Involvement 1
5.11 PrM Maintenance Strategy 1
5.12 PrM Maintenance Strategy - Communication & Understanding 2
5.13 PrM Support for AM 1
5.14 Optimised Line Philosophy & V Curve 1
5.15 Centre-Lining & the Elimination of Adjustments 3
5.16 SMED 1
5.0
Machin
e
Level 1 Level 2 Level 3 Level4 Level 5
Not Started Beginning Competent Proficient Expert
0 Points 1 Point 2 Points 3 Points 4 Points
Next Steps for AM – Practitioner training….
Princes Manufacturing System - Asset Management Development Roadmap
Pillar Flow Phase
Asset
Management
Embed EEM
Process
Preparation for
AM, PrM -
training &
education.
AM
Practitioners
development
Preparation Phase Stability Phase
RCA Data Base Causal
Factor Analysis
EEM Start
Deployment
Prep. For EEM
training &
education
AM Program Deployed. Aligned
to PrM Ledger development &
SAP-PM
PrM Step 0
Preparation
PrM Step 2
Apollo RCA
Focus
Establish RCA
Data Base
MEOSI Skill
Development
Program
PrM Step 1
Supporting
AM
PrM Step 3
Maintenance
Standards
Effective
Stores
Management
PrM
Practitioners
development
PrM Step 4
Countermeasures
For Machine Weakness
Asset
Management
Awareness for
Leadership
Teams
5 day PrM
Princes
Practitioner
training
5 day EEM
Princes
Practitioner
training
5 Day Certified
Princes AM
Practitioner
training
2 Day Apollo
RCA training
Day 1 Monday
Day 2 Tuesday Day 3 Wednesday Day 4 Thursday Day 5 Friday
C
o
n
t e
n
t
FACTORY Based
Arrival & Registration
Welcome & Introductions
Introduction to Autonomous Maintenance & Organisation
AM Preparation – Step 0
Team Presentations
FACTORY Based
Learning Review
Step 1 Initial Cleaning
Team Presentations
FACTORY Based
Learning Review Step 2 Reducing the time to clean
Team Presentations
FACTORY Based
Learning Review Step 3 Standards and Lubrication Step Auditing
Team Presentations
FACTORY Based
Learning Review Examination
100 Day Planning
Factory Presentation from teams
Closing awards
O
u
t p
u
t
Basic understanding of AM
Risk assessments
Initial education
Step 0 Activity Board
Clean Machine & Identified problems
Step 1 Activity Board
Machine Improvements
Step 2 Activity Board
Step 3 Activity Board
Step Audits Step Auditing Activity Board
Certified Practitioners
100 Day forward Plan
A
M 08:00 Team Time 08:00 Team Time 08:00 Team Time 08:00 Team Time
09:00 Registration & Coffee
Welcome, Introductions
& safety Brief Introduction to AM
08:30 Team Learning Review
Step 1 Introduction
Step 1 Practical Briefing
Team Preparation
08:30 Team Learning review
Step 2 Introduction
Step 2 Practical Briefing
Team Preparation
08:30 Team Learning Review
Step 3 Introduction
Step 3 Practical Briefing
Team preparation
08:30 Examination (1hr)
10:15 Coffee 10:30 Coffee 10:30 Coffee 10:30 Coffee 09:30 Coffee
10:30 AM Preparation - Step 0
Step 0 Practical Briefing 10:45 Step 1 Practical 10:45 Step 2 Practical 10:45 Step 3 Practical
10:00 100 Day Planning
100 Day Plan practical Final Presentation Prep.
11:15 Step 0 Practical Team Preparation
12:20 & Lunch 12:30 Lunch 12:30 Lunch 12:30 Lunch 12:30 Lunch
P
M 13:15 Step 0 Practical 13:15 Step 1 Practical Continued 13:15 Step 2 Practical Continued
13:15 Introduction to Step Auditing
Step Audit Practical Briefing
Team Preparation
13:30
14:30
Final Presentations
Awards
15:00 Coffee (Informal) 15:00 Coffee (Informal) 15:00 Coffee (Informal) 15:00 Coffee (Informal) 15:00 Close & Depart
15:20 Step 0 Practical Continued 15:20 Step 1 Practical Continued 15:20 Step 2 Practical Continued 15:15 Step Audit Practical continued
16:30
17:30
Team Presentations
Close
16:30
17:30
Team Presentations
Close
16:30
17:30
Team Presentations
Close
17:15
18:00
Team Presentations
Close
Machine Stoppage
13:30 – 16:00 Observation & Minor Stoppage
Machine Stoppage
11:00 – 15:00 Locked-off & isolated for initial clean
Machine Stoppage
10:45 – 12:30 Minor Stoppage
13:00 – 15:00 Locked-off & isolated
Machine Stoppage
10:45 – 12:30 Minor Stoppage
Standard work for the 5
day AM Practitioner
workshop
Then continually track AM progress…..Measures & “Show
& Tell”.
Month or Week no Jul-13 Aug-13 Sep-13 Oct-13 Nov-13 Dec-13 Jan-14 Feb-14 Mar-14 Apr-14 May-14 Jun-14 Jul-14
No/Project Machine Description Criticallity Planned Start Date Saving Target AM Steps Planned Intro Zero Trn Zero prac
AM Steps Actual Intro Zero Trn Zero prac Step 0 85%
Ledger Development Planned
Ledger Development Actual
Centrelining Planned
Centrelining Actual
Month or Week no Jul-13 Aug-13 Sep-13 Oct-13 Nov-13 Dec-13 Jan-14 Feb-14 Mar-14 Apr-14 May-14 Jun-14 Jul-14
No/Project Machine Description Criticallity Planned Start Date Saving Target AM Steps Planned Intro Zero
AM Steps Actual Intro Zero started Zero 85%
Ledger Development Planned
BLedger Development Actual
Centrelining Planned
Centrelining Actual
Autonomous Maintenance - Status Summary
B Shift
RFCline 1 RFC
Rinser AA
Filler AA
Capper A
Oct-13 5% reduction in downtime
Autonomous Maintenance - Status Summary
C Shift Line 2 Palletiser Aug-13 5% reduction in downtime
Asset Management meeting rotates around
group.
Every meeting includes a “Go See”.
Meetings led by senior Manufacturing &
Engineering Directors.
All sites , within scope, represented at the
meeting.
Princes AM journey – our learnings so far for 4.0
Soft Learnings -
Find a change model, use it
& stick to it.
Start from “why”.
It’s Important everyone
learns together.
All “tools” require good
leadership & behaviour.
Principles are powerful.
Better a small job done well
than a big one done badly.
Hard Learnings -
The little things really do eat
your lunch.
Understand your losses –
its not as easy as you think.
Criticality is critical.
Centrelining works.
The ledgers are especially
important but are very hard
work.
Next steps…
AM
PrM
EEM
Improving Delivery of -
Equipment Competent
Workforce.
Next - Leadership &
Behaviour development.
Improving Delivery of -
Specialist Support.
Next - Full CMMS integration
Improving Delivery of -
Flawless Operation
From Day One. Next - Link to
Voice of the Customer