1. Offline Activity Key Focus Problem Description 3 Key things the
Project Name:
Team:
Offline Activity
Matt Croose, & Claire Taylor
Key Focus
What we have
completed
Problem Description
Currently there is a serious reduction in effective performance due to excessive time spent executing offline activity
The Key focus areas are as follows:
Transition to all online coding activity
Reduction in non value added activity
Increased effective utilisation of staff
Waste reduction e.g. transport, inspections and materials
Utilisation of floor space
Streamline the process
Identifying improvement phases by proving the online coding concept
We have assessed where we would like the company to go and hit its What Does Good Looks Like – All online activity.
Identifying the level of waste and cost to the company in current state.
Analysed the requirement to move to online coding
3 Key things the
project will achieve
Improvements in customer lead time
Increased productivity
Increased utilisation of staff
Resources required to complete the project
Return on Investment
Effective buy in and employee engagement to the Lean process around site, assistance in driving the project forward by the SLT. Investment in new technology.
The (projected) ROI for this project over a 5 year period - £800,000 - £1.5 million

2. Green Belt ROI LEAFLET READING– POTENTIAL ROI Jan 2015 – Jan 2016
Project Name:
Team:
Offline Activity
Matt Croose, & Claire Taylor
LEAFLET READING– POTENTIAL ROI Jan 2015 – Jan 2016
ROI FOR REMOVAL OF OFFLINE LEAFLET READING
Currently 2069 hours are spent running offline leaflet reading
A Minimum of 2 hours are spent – booking, setting, challenging.
Utilising an average of £20ph/person.
This activity has been run in over 681 works orders between January 2015 and January 2016.
If we transition to complete online leaflet reading or supplier sampling then the following saving can be made.
Over a 5 year period it has been calculated using figures from JDE PCI can make a saving of: £343,100.00

3. Green Belt ROI HAPA PRINTING – POTENTIAL ROI Jan 2015 – Jan 2016
Project Name:
Team:
Offline Activity
Matt Croose, & Claire Taylor
HAPA PRINTING – POTENTIAL ROI Jan 2015 – Jan 2016
ROI FOR REMOVAL OF OFFLINE HAPA PRINTING
Currently 2787 hours are spent running offline HAPA activity
A Minimum of 2 hours are spent – booking, setting, challenging
Utilising an average of £20ph/person.
This activity has been run in over 400 works orders between January 2015 and January 2016.
If we transition to complete online HAPA activity then the following saving can be made.
Over a 5 year period it has been calculated using figures from JDE PCI can make a saving of: £358,700.00

4. Green Belt ROI CARTON CODING– POTENTIAL ROI Jan 2015 – Jan 2016
Project Name:
Team:
Offline Activity
Matt Croose, & Claire Taylor
CARTON CODING– POTENTIAL ROI Jan 2015 – Jan 2016
ROI FOR REMOVAL OF OFFLINE CARTON CODING
Currently 1428 hours are spent running offline carton coding
A Minimum of 2 hours are spent – booking, setting, challenging
Utilising an average of £20ph/person.
This activity has been run in over 325 works orders between January 2015 and January 2016.
If we transition to complete online carton coding then the following saving can be made.
Over a 5 year period it has been calculated using figures from JDE PCI can make a saving of: £207,800.00

5. Over a 5 year period it has been calculated PCI can make a saving of:
Green Belt ROI
Project Name:
Team:
Offline Activity
Matt Croose, & Claire Taylor
PAPERWORK/PRE PRODUCTION– POTENTIAL ROI Jan 2015 – Jan 2016
Currently 4 Hours is spent per works order. All the produced works orders contain offline paperwork/activity. It has been calculated an average of 985 works orders have been run over the past year.
Utilising an average of 1 member per department - £20 PH/PP
985 works orders x 4 hour= 3940 hours
3940 x £20 PH/PP = £78,800 (per annum)
If we transition to complete online carton coding then the paperwork activity and extra physical works per department would be reduced.
Over a 5 year period it has been calculated PCI can make a saving of:
£394,000.00

6. Green Belt ROI Future State - WDGLL ONLINE ACTIVITY LEAFLET READING
Project Name:
Team:
Offline Activity
Matt Croose, & Claire Taylor
Future State - WDGLL
ONLINE ACTIVITY
LEAFLET READING
CARTON CODING
HAPA PRINTING
Suppliers to perform inspection of components.
All coding to be performed online using newly installed equipment.
Online hapa installations have been performed on site and confirmed as effective.
Inclusion of certificate inside of BPRs, similar process to COFA and COFC.
Reduction in paperwork production and warehouse picks to perform offline coding.
Reduction in wasted time and resource, this process wastes the largest amount of time - offline
Reduction is quantity of quality checks by PCI – we used approved suppliers.
Quantity of trained staff will increase as the equipment will become our “Normal cubicle plan”
Ordering of plain foil will reduce the levels of quality inspections prior to operation, only plain foil will be require or partially printed.
Reduction in over processing and utilisation of staff and skills.
Will no loner impact the primary production cubicle waiting for offline components
Impact to cubicles waiting is reduced and therefor OEE is increased

7. Project issues
Project Name:
Team:
Offline Activity
Matt Croose, & Claire Taylor
ISSUES
Data collection – Batch sizes and running speeds difficult to attain
JDE – Reports indicative not exact
Time spent – We could only estimate as some areas did not feedback
Shift Report – Not easy to understand
Who has been trained is unclear
Processes are not being followed e.g. number of checks for quality
Buy in from departments to support our Green belt project
Not being able to spend 50% of our time on project
Not aware of CAPEX projects that are related to removal of offline
Return on investment is an estimate only due to above
This project has been a lean activity before and not implemented. Project Team – Leon Rees and Darren Owens.

8. Lessons Learnt Lessons Learnt
Project Name:
Team:
Offline Activity
Matt Croose, & Claire Taylor
Lessons Learnt
Need discussions with manager on how to spend 50% of time and our involvements before starting training and projects.
Scope of project needed to be identified sooner.
No project sponsor or regular meetings.
Need for regular meetings with SLT or project sponsor.
Need buy in from all departments to support our Green belt project.
Data requested needs to be measurable and understandable.
Great working as a team to share our knowledge and experience.
Large amount of opportunity for Continuous Improvements on site e.g. number in cubicles, 5S, NPI’s, review processes.
Need to share our knowledge and learning with others.