Objective

To complete a PPIG Line Survey and identify areas that when completed could improve the performance of a chosen line.

 

Opportunity

The PPIG Line Survey has been developed over the last 3 years to cover an extensive list of areas/ activities both directly and indirectly associated with the production line.

There is therefore a requirement for the client to provide certain information pertaining to the line in question. 3.8.5. gives a full list of areas covered and identifies those that require additional information from the client.

The information gathered during the PPIG Line Survey is assessed with any potential improvement identified and transferred onto the unique Line Improvement Plan. (LIP) identifies the categories used within the LIP.

In conjunction with the client the LIP can then be prioritised and action steps agreed.

 

Scope of Work

PPIG offer to undertake the survey of a line and identify gaps in performance / opportunity for improvement. PPIG will also estimate the potential improvement and suggest the potential timescale to completion of the improvement.

The PPIG line survey has been designed to minimise disruption of production during the survey therefore no special planning is required.

All documentation generated during the Line Survey and Analyses remains the property of the client and will be presented within one of the following documents:

    1. Line Survey Folder

    2. Line Improvement Plan

 

Milestones / Timescales

  • Complete Line Survey / 5 days onsite
  • Analyse data from client and Line Survey  / 5 days (min 3 days onsite)
  • Deliver Line Improvement Plan / 5 days (min 2 days on site)

Timescales are subject to agreement with client following the identification of the line to be surveyed.

 

Areas Covered Within Survey

Note: * identifies those areas that require information from the Client.

    1    General Line Information

    1.1 Manning Levels

    1.2 Product Range

    1.3 Line Drawing*

 

    2    Historical Documentation

    2.1 Line Efficiencies YTD*

    2.2 Product Scheduling & Volumes*

    2.3 Efficiencies by Size*

    2.4 Current Line Improvement Plan*

    2.5 Training Information*

    2.6 Other efficiency / Effectiveness Measurements YTD *

    2.7 Production Records*

    2.8 Other reports & studies*

    2.9 Changeover Data *

     

    3    Current Operating Procedures

    3.1 Current Procedures*

    3.2 Procedure Actions

    3.3 Skills Actions

    3.4 Available procedure

 

    4    Quality Standards

    4.1 List of Material Concerns*

    4.2 Line Quality checks

    4.3 Line Samples

    4.4 Current Product Quality Assessment

     

    5    Maintenance and Parts Record (Information from client following discussion)*

    5.1 PPM Routine

    5.2 Overhauls

    5.3 Parts Issue Process Review

    5.4 Resource Requirement

    5.5 Revenue Spend

    5.6 Maintenance Spend by Machine

     

    6    Line Equipment Survey

    6.1 Machine Details

    6.2 Machine Condition

    6.3 Line Balancing

    6.4 Future Potential

 

    7    Material Rationalisation Opportunities

    7.1 Product Similarities

    7.2 Current Problem Areas

    7.3 Potential Cost Savings

    7.4 Supplier Development Opportunities

 

    8    Additional Information

    8.1 Spirit Process

    8.2 Asset Performance Developments

    8.3  Asset Register

List of Categories Used Within the PPIG Line Improvement Plan

 

  • Operating Procedures
  • Performance Standards
  • Product Range
  • Product Rationalisation
  • Optimisation Opportunities
  • Line Modification
  • Equipment Assessment
  • 5 S
  • Autonomous Maintenance
  • Process Improvement Activities
  • Quick Changeover Methodology
  • Planning Performance
  • Planned Preventative Maintenance
  • Maintenance Spares
  • Measures (Ex. Quality, Cost, Service)
  • Ownership of Process, Problems & Goals
  • Training
  • Monitoring
  • Operation Changes
  • Brand Change
  • Quality Assurance
  • Material & Spirit Supply
  • Waste
  • Manufacturing Capability
  • Related Projects

 

Note:  The above list sets out to cover as many areas as possible and can be extended/contracted to suit the individual clients own requirement. For the purpose of the LIP only those heading used/ agreed with the client will be incorporated.