4H Short Interval Control Management Routines 4H Short Interval Control Interactive Training February, 2015 Information that is accessible, understandable, actionable, and visible. Classified - Unclassified

Why we need Management Routines? To ensure teams are focusing on the right things at the right time What gets measured, gets managed; what gets managed can be maintained and improved upon Weekly Strategic Meeting 24H Review SIC SIC SIC Our focus today is SIC SIC Classified - Unclassified

Forward Thinking… Symptom Questions to change focus Deeper / More specific: ‘Why, why, why…’ ‘What was the root cause?’ Future / Planning: ‘What is likely to cause the biggest problem today/this week unless we take action?’ ‘What is our proactive action that will prevent this from happening again?’ Language: This happened, that happened (Superficial / Presenting problem) Example: We had many stops due to fallen bottles at the in-feed Language: We’ll investigate, look into, monitor… (Non specific, meaningless) Example: We are going to monitor the fallen bottle issue Depth Past / Reporting Future / Planning Time Language: The cause of the problem was…. The real issue was…. Example: Conveyor wear combined with incorrect planned maintenance frequency caused fallen bottles at the in-feed Language: Our root cause fix is to…. The 100 yr fix is planned for… A team will add most value, when they focus in the future / planning (bottom right) - often based on root cause understanding (bottom center) Example: We are changing the conveyor slat at our next maintenance and the replacement schedule has been reduced accordingly Root Cause Classified - Unclassified

Classified - Unclassified 4H SIC Overview 4H Short Interval Control (SIC) is a Forward Thinking process… 4H SIC (<5 Min) is based on the TPM Six Big Losses Participants: Production Supervisor Mechanic Purpose: Analyze data since the last 4H SIC Provide focus until next 4H SIC Generate Actions and Set Targets Some Of the Steps: Check Unknown Loss – caused by incorrect LIS data Check Unassigned Events – events which are not captured automatically and were not filled out by operators Close Actions from previous 4 SIC Analyze the Six Big Losses – utilize Pareto and Trend Charts Generate Actions – in average one or two actions (but no more than three) 4H SIC “unclouds” our Crystal Ball Classified - Unclassified

Classified - Unclassified 4H SIC Tips 4H Short Interval Control (SIC) is a Forward Thinking process… Tips to make SIC process most effective: Focus - only on what is most important Know your numbers – “Normal” for Machine Efficiency & MTBF (target returning to “normal”) The Target Type for Machine’s Breakdowns is Efficiency and for Machine’s Minor Stops is MTBF Act now - close actions fast Less is more – better to properly resolve one issue rather than take on more and not do them well Escalate – if an action is important and not getting resolved, escalate to the 24H Review (morning meeting) Classified - Unclassified

Filler “Normal” MTBF is 26 Min Determine the “Normal” for Machine Efficiency & MTBF Ignore “outliers” Ignore ‘outliers’ Filler “Normal” MTBF is 26 Min Labeller “Normal” MTBF is 20 Min Weekly MTBF – 12 weeks Create a table with “Normal” Efficiency & MTBF for main machines Daily MTBF – 12 weeks Classified - Unclassified

4H SIC “Crystal ball” thinking 4H Short Interval Control (SIC) is a Forward Thinking process… Use historical data to predict what is most likely to affect performance in the following 4H Thinking process & considerations: Most recent data is most relevant to predicting the future Planned downtime events (orange) are mental ‘resets’ for considering relevance (depending on the kind of PDT event) Frequent minor stops are more likely to repeat than Breakdowns Reduce the relevance for stops that look like they’ve been resolved Key question: ‘Based on this data, what is likely to cause the greatest loss in the next 4 hours?’ Classified - Unclassified

Classified - Unclassified 4H SIC Feedback Six production managers have graded 4H SIC features (0 to 5 – highest) 1.   Forward Thinking - 4.6 2.   Provides Actionable Information – 4.6 3.   Provides relevant Checking points – 4.4 4.   Easy to understand – 4.2 5.   Easy to implement – 4.2 6.   Serves as a Resources Allocation – 4.4 7.   Focus on the right things at the right time – 4.4 8.   Tracks the LIS 4H SIC and provides statistics – 4.6 9.   Effective Action Log – 4.2 10. Overall – 4.4 Classified - Unclassified

Classified - Unclassified Q&A Classified - Unclassified

Classified - Unclassified Help Report 1 The first Report is the Help Report 3 Select the SIC 4H_LineX Report 2 We can open the Action Track at any time Classified - Unclassified

Classified - Unclassified Start 4H SIC 5 To perform SIC 4H navigate from left (Start) to right (Stop) 1 Loss Area will be visible all the time 2 Pareto shows how we penalize the machine for stopping the line 3 Pareto shows the Frequency for Machines Down Time Reasons 4 Pareto shows the Duration for Machines Down Time Reasons Classified - Unclassified

Classified - Unclassified Check Unknown Loss Add Action #1 Chris will contact CEG to address the Unknown Loss issue Classified - Unclassified

Check Unassigned Events No Action Required Classified - Unclassified

Classified - Unclassified Close Actions Classified - Unclassified

Classified - Unclassified Close Actions 2 Click on DT to start the Down Time Analysis 1 Review Open Actions Close off Actions Are actions completed? If not, why? Was the target achieved? If not, what other action is required? Classified - Unclassified

Down Time Loss Analysis 1 Observe the top 3 Machines Penalty 2 Observe Machines’ Penalty and DT Trends. We will focus on Labeler #2 and Sico AV 3 Filler – There is already an open Action Classified - Unclassified

Down Time Loss Analysis – Labeler #2 Select the Labeler #2 KPIs by clicking on one of the two Push Buttons Classified - Unclassified

Down Time Loss Analysis – Labeler #2 Observe Labeler #2 MTBF, Internal Fault Reasons & Trend Chart Classified - Unclassified

Down Time Loss Analysis – Labeler #2 Add Action #2 Be specific, add responsible, end date & time and target Adam will increase Labeler #1 MTBF to 20 Min by 1/31/15 Classified - Unclassified

Down Time Loss Analysis – Sico AV Observe MTBF, Internal Fault Reasons & Trend Cart Classified - Unclassified

Down Time Loss Analysis – Sico AV Click on SPD to start the Speed Loss Analysis SICO AV Add Action #3 Reed will increase Sico AV MTBF to 25 Min by 02/1 Classified - Unclassified

Classified - Unclassified Speed Loss Analysis Observe the Machines with a Yellow Bar graph. We will focus on Filler Labelers and Packer Classified - Unclassified

Speed Loss Analysis - Filler No Action needed Blow Molder is the critical machine and the filler is capable (when needed) to run faster than Blow Molder. Classified - Unclassified

Speed Loss Analysis – Labeler #1 & #2 Close the screens and select Packer #1 1 Action #4 Scott will increase Labeler #1 speed to 550 cpm by 02/01 Classified - Unclassified

Speed Loss Analysis – Packer #1 2 We will have a PDT (Step 1) in the next 4 H 1 No Action is taken at this time Lack of maintenance resources; we will act at the first opportunity. Packer #1 Max Speed is 1075 cpm Classified - Unclassified

PDT Loss Analysis – Step 1 3 Stop the SIC 17 2 Step 1 duration is below Target 1 Planned Downtime Was the last PDT to target? If not, why? How can you ensure that the issues are solved for the next time Classified - Unclassified

Classified - Unclassified Actions Q&A Action #1 – Chris will contact CEG to address the Unknown Loss issue Action #2 – Adam will increase Labeler #1 MTBF to 20 Min by 1/31/15 Action #3 – Reed will increase Sico AV MTBF to 25 Min by 02/1 Action #4 – Scott will increase Labeler #1 speed to 550 cpm by 02/01 Q&A Classified - Unclassified

Example - Rejects Loss Analysis Just an Example !!! Is the Rejects Loss < Target? Yes No Classified - Unclassified

Classified - Unclassified 4H SIC Track 1 2 SIC takes too long. Most likely is caused by lack of training SIC is too short 5 5 5 26 2.5 2 Classified - Unclassified

Classified - Unclassified 4H SIC Track Trend Chart allows to monitor the SIC 26 2.5 2 Classified - Unclassified

Classified - Unclassified Q&A Classified - Unclassified

Classified - Unclassified Marietta Plant - 4H SIC Example Classified - Unclassified

Classified - Unclassified Check Unknown Loss Q&A No Action Required Classified - Unclassified

Check Unassigned Events Q&A Add Action #1 Adam will reduce the unassigned events to less than 5 by 1/28/15 Classified - Unclassified

Classified - Unclassified Close Actions Q&A Review Open Actions Close off Palletizer #2 Action Classified - Unclassified

Down Time Loss Analysis Q&A Observe the top 3 Machines Penalty Observe Machines’ Penalty and DT Trends We will focus on Labeler #1 and Wrapper #2 Classified - Unclassified

Down Time Loss Analysis – Labeler #1 Q&A Observe Labeler’s Efficiency, Reasons for Internal Fault & Trend Chart Classified - Unclassified

Down Time Loss Analysis – Labeler #1 Q&A Add Action #2 Reed will increase Labeler #1 efficiency to 89% by 1/28/15 Classified - Unclassified

Down Time Loss Analysis – Wrapper #2 Q&A Observe Wrapper’s Efficiency, Reasons for Internal Fault & Trend Chart Classified - Unclassified

Down Time Loss Analysis – Wrapper #2 Q&A Add Action #3 Scott will increase Wrapper’s Efficiency to 93% by 01/28 Classified - Unclassified

Classified - Unclassified Speed Loss Analysis Q&A Observe the Machines with a Yellow Bar graph. We will focus on Filler and Packer Classified - Unclassified

Speed Loss Analysis - Filler Q&A No Action needed The filler speed issue was addressed 70 minutes ago. Classified - Unclassified

Speed Loss Analysis – Packer #1 Q&A No Action is taken at this time Lack of maintenance resources; we will act at the first opportunity. Classified - Unclassified

PDT Loss Analysis – Step 3 Cold Q&A No Action needed In the next 4H we will have a Step 3 Cold; In the last three Step 3 Cold we were on Target. Classified - Unclassified

Classified - Unclassified Actions Q&A Action #1 – Adam will reduce the unknown events to less than 5 by 1/28/15 Action #2 – Reed will increase Labeler #1 efficiency to 89% by 1/28/15 Action #3 – Scott will increase Wrapper #2 efficiency to 93% by 1/28/15 Q&A Classified - Unclassified

Classified - Unclassified Q&A Classified - Unclassified