FOOD INDUSTRY
Challenge
Food Industry company needed to improve their Sanitation performance. Current sanitation takes 8 to 12 hours (starting at midnight) which greatly reduces uptime and productivity. Create a SYSTEM to EASILY manage resources due to load variation.
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Solution:
Complete a Sanitation Event that analyzes all activity and issues occurring during the sanitation. Reduce sanitation time to no more than 4 hrs. Right size Sanitation resources and develop a System to manage those resources
Results:
• Increased production accounts for $61M increase in revenue.
• Reduction of 24 Temporary Employees (a $672K annual
improvement)
• 20% Reduction in permanent workforce (redeployed to
production)
• Eliminated obstacles to performance of efficient sanitation.
• Developed NEW standard work for improved organization.
• Established Sanitation Timeline with expected stage gates.
In order to make good decisions, we needed to establish what was happening currently, which
meant the team MUST work the night hours during sanitation to collect observation data.
Below is a small example of the data that was collected to be analyzed.
In order to make good decisions, we needed to establish what was happening currently, which meant the team MUST work the night hours during sanitation to collect observation data. Below is a small example of the data that was collected to be analyzed.
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During the observations, we were able to see issues with maintenance, organization, plumbing
and operator performance (due to no written standard work). Countermeasures to all these
issues resulted in some great improvements. There was still a problem, but we had to develop a way to manage variation of equipment needing sanitation and product variation which would
require different layouts. different equipment needing sanitation. We also had to develop a
tool to be used by management to establish staffing requirements due to this load variation.
We developed a management tool that would calculate staffing, time and equipment to be
sanitized by product type. This tools was taught to management and we monitored the use of
the tool for about a month until it became standard work for management. This along with
some trend charts in our Business Control Center (sometimes called a “War Room”) became the
sustainment methodology for this event.
Below is a graphic of the productivity time gains that were accomplished by reducing the
OVERALL sanitation.