WCM Blitz Playbook 20190705 v2

WCM BLITZ
Deployment Playbook
1
CONTENT
Playbook structure and

1 guidelines
2 WCM Blitz approach overview
3 WCM Blitz principles
4 Weekly plans
2
1. PLAYBOOK
STRUCTURE AND
GUIDELINES
3
Optional
1. PLAYBOOK STRUCTURE
AND GUIDELINES
4
VERSION CONTROL
Title WCM Blitz Deployment Playbook

Description 16 week deployment playbook for the WCM Blitz programme
Created By EY
Date Created 11 February 2019
Maintained By Zoe Platts (Unilever)
Version Number Modified By Modifications Made Date Modified Status

v1.0 Daniel Seeney (EY) First complete draft of playbook 27/02/2019 Master - Draft
Updated with:
- learnings from WCM Blitz deployment in Port
v2.0 Stan Simonski (EY) 28/02/2019 Master
Sunlight
- Feedback from Unilever Port Sunlight team
5
USING THE DEPLOYMENT PLAYBOOK
ABBREVIATIONS AND VOCABULARY INDEX
AM Autonomous Maintenance LS Line Settings
BDE Breakdown Elimination LT Line Team
CBP Current Best Practice LTC Line Team Coach
CI Continuous Improvement LTL Line Team Lead
CIL Clean, Inspect, Lubricate OEE Overall Equipment Effectiveness
CO Changeover OM Operations Manager
EM Engineering Manager PE Process Engineer
FD Factory Director PIL Process Improvement Lead
FI Focussed Improvement PM Professional Maintenance
FM Finance Manager SMED Single Minute Exchange of Dies
FT Focus Technician TM Tags Management
FV Factory Vision UL Unilever
EHS Environment, Health and Safety VR Volume Reliability
HC Health Check WCM World Class Manufacturing
HRM HR Manager WCM MGR WCM Manager
KPI Key Performance Indicator
6
THE PLAYBOOK PROVIDES CLEAR GUIDANCE ON THE WEEKLY
ACTIVITIES TO DEPLOY WCM BLITZ AND SUSTAIN THE RESULTS
1 Overview 3 Activities Planning Considerations
Provide week by week guidance for the deployment of WCM • Weekly drumbeat timings should be adjusted, in association
capabilities and tools within a 16-weeks ‘Blitz’ with the team, based on the local shift patterns - keeping to
The play book should be used together with the WCM Blitz the suggested structure as closely as possible
“Current Best Practice” guidebook • The deployment of Work Process and tools must occur within
the designated week. Any changes should be signed off by the
deployment leadership team
3 Structure • Conduct weekly Next Week Planning session with the
activities required based on staff availability
The Playbook consists of 16 weekly-plans defining the key
• The next week plan should be displayed in the daily meeting
activities that will take place in each week.
room
Each week has three sections:
• Promote and encourage attendance by the Senior Leadership
1. Overview showing what work processes and tools will be Team to open activities to develop their exposure and
introduced during the week knowledge of the Blitz approach and WCM
2. Detailed Work Plan lists:
• The activities to be planned in the week
• The type of coaching required
• Required supporting material
• Required attendees for the sessions
3. Weekly Drumbeat showing when activities should be planned,
this evolves throughout the Playbook as additional activities
are deployed
7
PLAYBOOK ASSUMPTIONS
Current Best Practice Factory Work Pattern
• The Playbook is the current leading practice • The Playbook timings are based on a Factory
for deploying the Blitz. with the following work pattern:
• The Playbook is designed to detail the type of • Line 9: 24 hours – 7 day a week operation
and timings for the activities required.
• Line 2: 24 hours – 7 day a week operation
• The daily timings of activities have been
• Line Team working hours of Monday to Friday
planned for the factory work pattern
5.30 to 18.30 to see all 3 shifts
described on this page.
• Two shifts:
• The implementation team should work with
the local factory team to adjust times to suit • Morning 6.00 to 18.00
their work pattern, but the timings should be
• Night 18.00 to 6.00
as close to those in the weekly drum beat as
possible. It is also recommended that the daily
and weekly order of events is preserved if any
adjustments to times are made. This is
especially true of the regular meetings and
Scheduled Stop timings
8
USING THE PLAYBOOK
WEEKLY DRUMBEAT TEMPLATE
Monday Tuesday Wednesday Thursday Friday
7.00 – 8.00
8.00 – 9.00
9.00 – 10.00
10.00 – 11.00
11.00 – 12.00
12.00 – 13.00
13.00 – 14.00
14.00 – 15.00
15.00 – 16.00
16.00 – 17.00
17.00 – 18.00
Night Shift
9
THE COACHING STRUCTURE WILL ENABLE THE SUCCESSFUL
AND SUSTAINABLE DEPLOYMENT OF THE WCM BLITZ
Deployment Coaching structure (to evolve over
Core Coaching Team
time)
1 Line Coaching Role
Factory
Each member of the Line Coaching Team will partner with Director
a member of the Line structure to: 2
Site
• Provide specific coaching and support
Engineering
• Provide advice on the SW owned by their Line Structure 4
Manager
partner
• Lead the SW Implementation Review session for the SW Central v
ManEX/
2 Senior coaches
Consultant
Factory Director and Engineering Manager act as senior Operations Factory
s WCM
coaches: Manager Engineering
1 Manager
(key coach) manager
• Provide specific coaching and support
• Lead ongoing health checks on SW
Auxiliary Coaching Team 3

PIL/AM
Site Pillar Process Focus
Pillar
3 SW coaching Leaders Engineer Technician
Owner
• Site pillar leaders provide expert advice on SW and tools
4 Accelerate progression
• Central ManEx team or consultants will be involved as
required to accelerate capability building or Enabled by Unilever coaching methodology
deployment activities.
10
2. BLITZ APPROACH
OVERVIEW
11
Optional
2. BLITZ APPROACH
OVERVIEW
12
HOLISTIC DEPLOYMENT PLAN ACROSS WORK PROCESS, TOOLS
AND LEADERSHIP TO ENABLE SUSTAINED RESULTS
Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8 Week 9 Week 10 Week 11 Week 12 Week 13 Week 14 Week 15 Week 16
Health and Safety Standards
AM Standards - Line Settings and Scales
Daily Line Meeting
AM Standards - Clean, Inspect, Lubricate
Tags Management
Leadership Health Checks
PM Standards - Breakdown Elimination
PM Standards - Professional Maintenance
Changeover Standards and SMED
Link to Cost Deployment
Problem Solving (Kaizen, 5G, 5W 1H, Why Why etc.)
Rate Strategy
OEE Calculation
Unilever Leadership Capability
Key Work Process Tool Leadershi

process s p
13
3. BLITZ PRINCIPLES
14
Optional
3. BLITZ PRINCIPLES
15
THE BLITZ PRINCIPLES WILL GUIDE THE BLITZ APPROACH AND
THE DECISIONS TAKEN DURING THE DEPLOYMENT
1 Enhance focus on work processes
2 WCM is the way we manage operations, not additional work
3 The WCM Blitz is enabled and sustained by the Unilever leadership model
Work processes, tools and leadership capabilities should be developed consistently to drive sustainable
4
improvements
5 Clear ownership for the completion of each task
6 Each employee is empowered to make decisions within their own area and leadership to provide support
7 Zero loss mindset from site leadership to operators will be the norm, not the exception
8 Data will be the life blood of WCM Blitz
16
4. WEEKLY PLANS
17
Optional
4. WEEKLY PLANS
18
WEEKLY PLAN USE GUIDANCE
House Keeping Colour Coding Legend
• Only major planned activities have been captured in the We have used a consistent colour coding mechanism to
weekly deployment plans provide a clear line of sight between actions and the plan.
• Plans are indicative, and timings should be adapted to The coding is:
the schedule restrictions of those implementing Activity Description Color
• Plans are adapted to meet the needs of Port Sunlight Tool/Work Any activity where a new tool or
Factory 1, and therefore effective transfer to other Process Work Process is deployed for the
factories might require adjustments Deployment first time
• All terminology has been aligned with that used in WCM Work Any Work Process that is delivered
Best Practices, or within the PSL site. Any Process regularly as part of this deployment
misalignments or gaps should be consulted with UL Execution playbook
document owners Any training or learning for site
Training and
leadership, factory leadership , line
Learning
leadership, or operators
Any workshops or working sessions
Workshop/
used within the programme to
Working
develop specific outcomes in
Session
relation to programme goals
Periods within this playbook where
Line Stops
we will plan for the line to stop
19
PREPARATION
20
PREPARATION WEEK
OVERVIEW
Tool/Work Process Deployed Key Activities Introduced Outcomes
• Current State Assessment (Prep) Work Process Related

• Leadership Blitz Introduction (Prep)
• Baseline understanding of WCM deployment status, focus on AM Pillar and
• Factory Strategy and Vision (Prep)
Current State Assessment meetings structure
• Daily Meeting Line Board (Prep)
• Roles Activation (Prep) • Critical gaps identified
• KPI & Data (Prep) Line team roles activation • Line Team roles and coaches identified prior to launch
• Factory Leadership Training (wk1) Deployment team roles activation • Defined and identified support roles for the deployment team
• Line Daily Meeting (wk1)
• Line Settings Work Process (wk1) Tools Related and Other Tasks
• Rate Strategy (wk1) • Leadership has basic understanding of key Blitz concepts, the 16-week plan, and
• OEE Calculation (wk1) key SW and tools to be deployed
• Operator Blitz Kick-off (wk1) Leadership Introduction to Blitz
• Leadership has basic understanding of key Unilever leadership concepts, such as
• Health and Safety (wk1) servant leadership, and the role of leaders in WCM
• CIL Work Process preparation(wk1)
Factory Strategy and Vision • Understand current state of factory strategy, vision and objectives
• Leadership Health Checks (wk2)
• AM CIL Work Process (wk2) Fix line speed • Locked line speed agreed with factory
• Scheduled Stop (wk2) • Understand current state KPI
• Tags Management(wk3) KPIs
• Establish key KAI and KPIs to be tracked
• Leadership Coaching Zone (wk3)
• Obtain line data and related information for 3 to 6 months
• Shift Handover (wk4) Review line event data for gaps
• Unilever Problem Solving (wk4) • Initial data cleaning and understanding of potential gaps and current losses
• PM BD SW (wk5)
• Weekly Meeting (wk6)
• PM Professional Maintenance (wk7)
• Changeover SW (wk8)
• Quarterly Cost Deployment Plan (wk8)
• SMED (wk9)
• Continuation Planning (wk15)
21
PREPARATION WEEK
DETAILED WORK PLAN *Types
Tool/ Work
Process
Work Process Training and Workshop/workin
Line Stops
execution Learning g session
deployment
Work Process Related Activities Type* Material Lead Format Duration Core People
Conduct Current State Deployment Shopfloor

Health Checks AM and daily meetings Health Checks 4-8 hours OM, WCM MGR, CI
Assessments/assessments Team health checks
Review current leadership FD, OM, EM, LT,

Deployment Working 90
standards/process & factory Working session Factory presentation LTC, WCM MGR,
Team session minutes
strategy HRM, FM
Review current state AM Pillar Deployment Working 120 AM Pillar Lead,

Working session WWCM Standards, Factory Processes and Standards
standards/deployment Team session minutes WCM MGR
Tools Related and Other

Activities
Establish Line Team, coaching

Deployment Working 90 FM, OM, EM, WCM
structure and extended Working session Roles Presentation, Roles descriptions
Team sessions minutes MGR, HRM
deployment team
Deployment Working 60 FM, EM, OM, WCM

Select lead line(s) Working session Blitz Overview Presentation
Team sessions minutes MGR, CI
Request initial data for lead Deployment Working 90 WCM MGR, Factory
Working session OEE calculation standards, Stops and MTBS calculation standard
line(s) Team sessions minutes data expert, CI
Factory data
Review LEDS data for gaps, Deployment Working 120
Working session OEE calculation standards Unilever and Reliability Engineering expert, CI, WCM
develop initial baseline Team sessions minutes
MGR
Deployment Working 90 FD, OM, CI, WCM

Confirm/establish locked rate Working session Rate Strategy Presentation
Team sessions minutes MGR, FT
Excel/physical PIL, WCM MGR,

Prepare Daily Meeting Board Prep Daily meeting board design and build Factory As needed
board Student support
Review relevant health and safety Working 60 EHS MGR, OM,

Prep Unilever health and safety tools and templates EHS manager
processes session minutes LTL, WCM MGR
22
PREP WEEK DRUMBEAT
Tool/ Work
*Types Process Line Stops
deployment
7.00 – 8.00
8.00 – 9.00
Current State Assessment

Current State Assessment
9.00 – 10.00 Preparation Week Kick-Off Daily Meeting Line Meetings (on the Preparation EHS
and Planning Session shopfloor)
10.00 – 11.00
Review current leadership Review LEDS data for
Prepare daily meeting
standards/process & gaps, develop initial
11.00 – 12.00 Establish Line Team and board
factory strategy baseline
coaching structure
12.00 – 13.00
Confirm Lead Line
13.00 – 14.00 Request initial data for Complete Current State Confirm/establish locked
lead line(s) Assessment activities on rate
14.00 – 15.00 the line
Current state assessment
AM Pillar Agree Daily Meeting Board
15.00 – 16.00 standards/deployment design
16.00 – 17.00
17.00 – 18.00
Night Shift
23
WEEK 1
24
WEEK 1
OVERVIEW

• Factory Strategy and Vision (Prep) • Introduce work processes and tools to Factory Leadership
Factory Leadership Training
• Daily Meeting Line Board (Prep) • Introduction to the Black Ops leadership
• Roles Activation (Prep) Validate daily meeting agenda and • Agree standard daily agenda for critical Daily Meeting activities for 16 Week
• KPI & Data (Prep) preparation process Schedule
• Factory Leadership Training (wk1)
• Line Daily Meeting (wk1) • Launch Line Daily Meeting meeting - Line Team review completion and
Line Daily Meeting deployment compliance of Work Process, previous 24 hour performance and create plan for
• Line Settings Work Process (wk1)
the day to prioritize corrective actions and allocate resources
• Rate Strategy (wk1)
• OEE Calculation (wk1) • Deploy process for managing line settings
• Operator Blitz Kick-off (wk1) Define Line Settings (LS) • Initial set of line settings for critical equipment
• Health and Safety (wk1) • Train operators in LS
Rate Strategy • Deploy agreed locked rate from preparation week
• AM CIL Work Process (wk2)
• Introduce SW to Line Operators and Focused Technicians
• Scheduled Stop (wk2)
Operators Blitz Kick-Off • Introduction to 16-weeks Blitz plant
• Tags Management(wk3)
• Collect feedback on current issues
• Shift Handover (wk4) • Training on H&S SW
• Unilever Problem Solving (wk4) Health and Safety • Soft launch of health and safety Work Process
• PM BD SW (wk5) • Agree on approach for embedding H&S work in AM and PM SW
• Weekly Meeting (wk6) Weekly Stops Planning and Preparation • Meeting to discuss plans for stops, and agree targets
Tools Related and Other Tasks
• Quarterly Cost Deployment Plan (wk8) • Introduce Line Team to data analytics process and produce clean data set to be
Data analytics introduction
• SMED (wk9) used for developing initial OEE Calculation and stops data
• Continuation Planning (wk15) Unilever leadership • Start developing Unilever leadership capabilities within the Line Team
25
WEEK 1
Tool/ Work
Process
Line Stops
deployment
Daily Meeting Overview Trainings

& Exercises
FD, OM, LT, EM,
Playbook Overview Training & Factory Leadership Deployment HRM, MM, QM,
Exercise Leadership Introduction Presentation PowerPoint 60 Mins
Training Team HS&EM, FM, WCM
Data analytics MGR
AM, PM, FI Overview Training

Line Daily Meeting Overview Deployment PowerPoint,
Line team training Daily Meeting Process, Daily Meeting Health Check 30 Mins LT, OM, WCM MGR
Training Team Excel
Dry-run (s) of Line Daily Meeting Deployment
Execute Daily Work Line Daily Meeting Coaching Points PowerPoint 20 Mins LT, LTC, OM
exercise with live data Team
Work Process Deployment
Line Settings Training LS Process, LSS HC, LS Templates PowerPoint 60 Mins LT, WCM MGR
Training Team
Work Process Deployment
Line settings initial deployment LS templates Excel 30 Mins LT
deployment Team
H&S SW Training Leadership Training H&S WCM standards EHS Manager PowerPoint 30 Mins LT, WCM MGR
Tool/Work Process As per WCM
H&S SW Soft Launch H&S WCM Tools Leadership 30 Mins LT
Deployment Standard
Deployment
Operator Blitz Kick-Off Workshop Blitz Overview Presentation PowerPoint 60 Mins LT
Team
Deployment As per WCM
CIL prep Training CIL process, templates 60 Mins LT, WCM MGR
Team Standard
Initial Cleaning and Inspection Line Team
Planning Initial Cleaning and Inspection overview PowerPoint 60 mins LTL
Planning Lead
Tools Related and Other Activities
Deployment
Rate deployment Deployment Rate Strategy Presentation, Line performance PowerPoint 60 Mins LT
Team
Deployment
Data analytics Tool deployment WCM OEE Calculation standard, Daily meetings board design PowerPoint 60 Mins LT, WCM MGR
Team
Deployment FD, OM, WCM
Weekly Deployment Review Progress Review Status Report PowerPoint 60 mins
Team MGR, EM
26
WEEK 1 DRUMBEAT
Tool/ Work
deployment
7.00 – 8.00
8.00 – 9.00 Lien Daily Meeting Dry

Lien Daily Meeting
Run
9.00 – 10.00 Operator Blitz Kick-Off
Factory Leadership
Training
Training: H&S Training
10.00 – 11.00
Data Analytics - OEE
Line Settings Calculation and Stops H&S Soft Launch
Deployment
Review data, develop
Training: Training:
11.00 – 12.00 Current State OEE
Line Daily Meeting Calculation CIL Preparation
12.00 – 13.00
Training: Preparation for Initial

13.00 – 14.00 Deploy fixed line rate
Line Settings & Scales Cleaning in week 2
Line daily meeting follow-up
14.00 – 15.00
15.00 – 16.00
Week Review and Next

16.00 – 17.00
Week Planning
17.00 – 18.00
Operator Blitz Kick-Off
Night Shift
27
WEEK 2
28
WEEK 2
OVERVIEW

• Validate WCM CIL template
• Deploy CIL tasks on pilot equipment
• Daily Meeting Line Board (Prep) AM CIL Work Process
• Implement process for recording and managing CIL’s
• Roles Activation (Prep)
• Train operators in CIL process
• KPI & Data (Prep)
• Factory Leadership Training (wk1) • Validate WCM Health Check template
Leadership Health Checks on Work
• Line Daily Meeting (wk1) • Train and coach leadership on expectations and process for Health Checks
Process
• Line Settings Work Process (wk1) • Deploy Health Checks process
• Rate Strategy (wk1) AM Step 2 – Initial Cleaning and • Conduct initial cleaning on the line as per AM Step 2 standard from WCM
• OEE Calculation (wk1) Inspection • Involve leaders in the event (OM, FM, HRM, Finance, EM)
• Operator Blitz Kick-off (wk1)
• Health and Safety (wk1) Tools Related and Other Tasks
• CIL Work Process preparation(wk1) • Train factory around the Scheduled Stop principal
• Leadership Health Checks (wk2) • Discuss timing of Scheduled Stops
• AM CIL Work Process (wk2) Scheduled Stop
• Deploy daily scheduled stops. Shiftly scheduled stops to be deployed 2-4 weeks
• Scheduled Stop (wk2) later
• Shift Handover (wk4)
• Unilever Problem Solving (wk4)
• PM BD SW (wk5)
• SMED (wk9)
29
WEEK 2
Tool/ Work
Process
Line Stops
deployment
Line Daily Meeting coaching – Deployment In-meeting

Line Coaching Line Daily Meeting Coaching Points 30 Mins LT, LTC
(Narrow Focus Maturity) Team coaching
Health Check Deployment Excel LT, LTC, OM, EM,
Leadership Health Check Daily Meeting Process & Health Check Current Leading Practice 60 Mins
Deployment Team Checklist WCM MGR
Excel
Deployment LTC, OM, EM, WCM
Health Check Overview training Training Health Check Process, Health Check Template Checklist, 30 Mins
Team MGR
PowerPoint
Deployment
CIL Overview training Training CIL Presentation, CIL SW Process, CIL Health Check, CIL template, PowerPoint 60 Mins LT, WCM MGR, OM
Team
Weekly Stops Prep and Planning Line Team As per WCM
Deployment Weekly stops schedule 60 Mins LT, WCM MGR
Meeting Deployment Leader Standard
PM activities alignment to Focused FT, Maintenance
Working session Existing PM standards PM Standards 60
updated scheduled stop Technician Planner
Activities
Scheduled Stop Presentation, Scheduled Stop Board, Scheduled Stop Deployment
Scheduled Stop Training PowerPoint 60 Mins LT, LTC
Definition Team
Line Team
Scheduled Stop Operator training Training Scheduled Stop Presentation PowerPoint 15 Mins LTL
Leader (LTL)
Line Team
Scheduled Stop Deployment Scheduled Stop Scheduled stop template, process Excel 30 Mins LT, EM
Leader (LTL)
LT, Selected
Line Team
Deep Clean & Inspection session Initial Cleaning Deployment Leading Practice – Scheduled Stop Checklist 240 Mins Factory Leaders,
Leader (LTL)
Engineers
Recurring Activities
Team MGR, EM
Deployment
Line Daily Meeting Execute Daily Work Line Daily Meeting Coaching Points Meeting board 30 Mins LT, LTC, OM
Team
Deployment
Line Daily Meeting Follow-Up Execute Daily Work Line Daily Meeting Coaching Points Meeting board 15 Mins LT
Team
30
WEEK 2 DRUMBEAT
Tool/ Work
deployment
7.00 – 8.00
Line Daily Meeting
Operator scheduled Stop
8.00 – 9.00 and CIL Training
Scheduled stop Scheduled stop

9.00 – 10.00 CIL Overview training
Weekly Stops Prep and
Maintenance working
10.00 – 11.00 Planning Meeting
session
Deployment AM Step 2
Initial Cleaning
11.00 – 12.00
12.00 – 13.00
Health Check Training
Deploy Leadership Health
13.00 – 14.00
Check
Daily Meeting Follow-Up
14.00 – 15.00
Preparation reparation for Implement CIL Tracking

15.00 – 16.00
initial cleaning Process and Tool
16.00 – 17.00
Week Planning
17.00 – 18.00
Night Shift
31
WEEK 3
32
WEEK 3
OVERVIEW

• Deploy process for identifying and managing tags
Tags Management Work Process • Embed TM process into the daily line meeting
• Deploy Health Check monitoring process
• KPI & Data (Prep) Tools Related and Other Tasks
• Allocate daily time for leadership, Line Team and other resources to engage the
• Line Daily Meeting (wk1) operators, coach on the floor, and embrace the servant leadership culture
Leadership Coaching Zone
• Line Settings Work Process (wk1) • Communicate Leadership Coaching Zone time to factory
• OEE Calculation (wk1)
• Health and Safety (wk1)
• PM BD SW (wk5)
• SMED (wk9)
33
WEEK 3
Tool/ Work
Process
Line Stops
deployment
Tags Management Overview Deployment

Training TM overview, TM Process, TM Health Check Presentation 60 Mins LT, LTC
training (TM) Team
FT, LTL,
Focused Working
Deploy tags planning cycle Deployment TM TM Presentation, Unilever Maintenance Plan 60 mins Maintenance
Technician session
Planner

Activities

Leadership Coaching Zone Training Unilever Leadership Presentation, Coaching on the Floor Presentation 30 Mins
Team MGR, EM, QM
Communicate Leadership Working FD, WCM MGR,

Deployment Communication mail template FD 60 Mins
Coaching Zone session OM, HRM

Team MGR, EM
Deployment
Team
Deployment
Team
Excel
Leadership Health Checks Health Check Health Checks Leadership 30 Mins LT, LTC
checklist
Line Team LT, LTC, Extended

Scheduled Stop SW Scheduled Stop Scheduled Stop SW Checklist 60 Mins
Lead deployment team
34
WEEK 3 DRUMBEAT
Tool/ Work
deployment
7.00 – 8.00
Line Daily Meeting
8.00 – 9.00
Scheduled stop
9.00 – 10.00
10.00 – 11.00 Training

Leadership Coaching Zone
Communication alignment
Training
11.00 – 12.00 on Leadership Coaching
TM Overview
Zone
12.00 – 13.00
Deploy weekly Tags

13.00 – 14.00 Management and PM Leadership Health Checks
planning
14.00 – 15.00
15.00 – 16.00

16.00 – 17.00
Week Planning
17.00 – 18.00
Night Shift
35
WEEK 4
36
WEEK 4
OVERVIEW

• Factory Strategy and Vision (Prep) Shift handover Meeting • Launch Sift Handover Meeting between Supervisors
• Roles Activation (Prep) Tools Related and Other Tasks
• Factory Leadership Training (wk1) • Train line team, engineers and line coaches on problem solving methodologies
Unilever Problem Solving and process
• Align problem solving triggers with current Breakdown Elimination process
• PM BD SW (wk5)
• SMED (wk9)
37
WEEK 4
Tool/ Work
Process
Line Stops
deployment
Deployment
Shift Handover standard training Training Shift Handover Standard PowerPoint 30 Mins LTL, Supervisors
Team
Deploy Shift Handover Standard Deployment Shift Handover Standard LTL PowerPoint 30 Mins LTL, Supervisors

Activities
PowerPoint,
problem
Unilever problem solving training Training Problem solving presentation/templets/examples UL Pillar Lead 60 Mins LT, LTC
solving board,
Excel
PowerPoint,
Problem solving deployment in Process problem
Deployment Problem solving presentation/templets/examples 60 Mins PE, WCM MGR
daily routine Engineer solving board,
Excel

Team MGR, EM
Deployment
Team
Deployment
Team
Excel
checklist
Weekly Tags and Maintenance Weekly Maintenance Focused

Weekly Maintenance Schedule, Tags log Excel 60 mins FT, MP
Planning Planning Technician

38
WEEK 4 DRUMBEAT
Tool/ Work
deployment
7.00 – 8.00
Line Daily Meeting
8.00 – 9.00 Leadership coaching zone
Scheduled stop
9.00 – 10.00
10.00 – 11.00
Conduct first problem
Training Embed problem solving solving session
11.00 – 12.00
Problem Solving into daily routine
12.00 – 13.00
Training
Weekly Tags and PM Shift Handover
13.00 – 14.00 Leadership Health Checks
Planning Meeting Deployment Shift
Handover
14.00 – 15.00
15.00 – 16.00

16.00 – 17.00
Week Planning
17.00 – 18.00
Night Shift
39
WEEK 5
40
WEEK 5
OVERVIEW

• Factory Strategy and Vision (Prep) CIL standards for night shift • Extend CIL standards to night shift
• Roles Activation (Prep) • Develop process to document all breakdowns
• KPI & Data (Prep) Breakdown Elimination SW • Establish breakdown trigger for in-depth analysis
• Factory Leadership Training (wk1) • Overview of breakdown elimination methodologies for line team
• Line Settings Work Process (wk1) Weekly meeting prep • Preparation session for weekly meeting
• OEE Calculation (wk1) Tools Related and Other Tasks
Scheduled stop in night shift • Deploy scheduled stop in the night shift
• PM BD SW (wk5)
• SMED (wk9)
41
WEEK 5
Tool/ Work
Process
Line Stops
deployment
Breakdown Elimination SW Deployment PowerPoint,

Training BD SW WCM Leading Practice 30 Mins LT, EM
Training Team Excel
Breakdown Elimination SW Deployment PowerPoint,

Deployment session Existing BDE material 90 Mins LT, EM
design Team Excel
Multiple
CIL Standards for night shift Deployment session CIL Leading Practice, Existing CIL standards LTL Excel LTL, Supervisors
sessions
Deployment PowerPoint,
Weekly meeting preparation Training Weekly meeting training, templates 60 Mins LT
Team Excel

Activities
Scheduled Stope deployment Deployment Multiple

CIL Standard Supervisor Excel LTL, Supervisor
night shift sessions sessions

Team MGR, EM
Deployment
Team
Deployment
Team
Excel
checklist


42
WEEK 5 DRUMBEAT
Tool/ Work
deployment
7.00 – 8.00
Line Daily Meeting
Scheduled stop
9.00 – 10.00
Training
Breakdown elimination Define night shift CIL
10.00 – 11.00
activities
Breakdown Elimination
Design Training
11.00 – 12.00
Weekly Meeting
12.00 – 13.00
Weekly Tags and PM

Planning Meeting
14.00 – 15.00
15.00 – 16.00

16.00 – 17.00
Week Planning
17.00 – 18.00
Night Shift Deploy planned stop
43
WEEK 6
44
WEEK 6
OVERVIEW

• Develop leadership Health Check checklist
PM Leadership Health Check • Train and coach leadership on expectations and process for Health Checks
• Deploy Health Checks on line
• Define terms of reference, attendees and inputs for weekly meeting
Weekly Meeting • Train teams on weekly meeting processes, per defined terms of reference
• Deploy weekly meeting
• PM BD SW (wk5)
• SMED (wk9)
45
WEEK 6
Tool/ Work
Process
Line Stops
deployment
Deployment PowerPoint,
Weekly meeting deployment Deployment Session Weekly meeting WCM Leading Practice 240 Mins LT
Team Weekly Board

Activities

Team MGR, EM
Deployment
Team
Deployment
Team
Excel
checklist


Line Team LT, LTC, OM, FD,

Weekly meeting Plan daily work KAI and KPI trends Excel 60 Mins
Lead EM
46
WEEK 6 DRUMBEAT
Tool/ Work
deployment
7.00 – 8.00
Line Daily Meeting
Scheduled stop
9.00 – 10.00
10.00 – 11.00
Weekly meeting Weekly meeting
preparation preparation
11.00 – 12.00
12.00 – 13.00
Weekly Tags and PM

Planning Meeting
Daily Meeting Follow-Up Daily Meeting Follow-Up
14.00 – 15.00 Weekly meeting
15.00 – 16.00

16.00 – 17.00
Week Planning
17.00 – 18.00
Night Shift Night Shift Planned Stop
47
WEEK 7
48
WEEK 7
OVERVIEW

• Factory Strategy and Vision (Prep) • Updated maintenance standards
Professional maintenance
• Daily Meeting Line Board (Prep) • Professional maintenance fully integrated into the loss elimination cycle
• PM BD SW (wk5)
• SMED (wk9)
49
WEEK 7
Tool/ Work
Process
Line Stops
deployment
FT, EM,
Professional Maintenance Deployment
Training PM Training Powerpoint 30 Mins Maintenance
Training team
Planner
Professional Maintenance
Focused FT, Maintenance
Deployment Deployment work PM standards Excel, CMMS 240 mins
Technician Planner

Activities

Team MGR, EM
Deployment
Team
Deployment
Team
Excel
checklist



Lead EM
Line Team
Weekly meeting preparation Plan daily work KAI and KPI, problem statements Excel 60 mins LT
Lead
50
WEEK 7 DRUMBEAT
Tool/ Work
deployment
7.00 – 8.00
Line Daily Meeting
Scheduled stop
9.00 – 10.00
Training:
PM overview
10.00 – 11.00
PM deployment – update PM Deployment – update
standards standards
11.00 – 12.00
12.00 – 13.00
Weekly Tags and PM Weekly meeting

Planning Meeting preparation
15.00 – 16.00

16.00 – 17.00
Week Planning
17.00 – 18.00
51
WEEK 8
52
WEEK 8
OVERVIEW

• Review changeover performance
Changeover SW • Training of operators on changeover standards
• Deploy changeover Work Process
Link to cost deployment plan • 90 day loss elimination plan for the line created
• PM BD SW (wk5)
• SMED (wk9)
53
WEEK 8
Tool/ Work
Process
Line Stops
deployment
Changeover SW - Leadership and Deployment

Training Changeover CBP PowerPoint 60 Mins LT
Operator Training Team
Deployment Changeover
Changeover SW - Deployment Deployment Changeover CBP, Changeover templates and checklist 60 Mins PE
team template
Preparation for link to cost Deployment Powerpoint,

Working session 90-day plan training 120 mins LT
deployment team Excel
Deployment Powerpoint,
Link to cost deployment training Training 90-day plan training 30 mins LT
team Excel
Deployment Powerpoint,
Prepare 90-days plan Deployment 90-day plan training 120 mins LT
team Excel
Activities
Process
Plan SMED workshop Working session SMED training Powerpoint 60 mins PE
Enginer

Team MGR, EM
Deployment
Team
Deployment
Team
Excel
checklist

Lead EM
Weekly meeting preparation Plan daily work KAI and KPI, problem statements
Line Team
Excel 60 mins LT 54
Lead
WEEK 8 DRUMBEAT
Tool/ Work
deployment
7.00 – 8.00
Line Daily Meeting
Scheduled stop
9.00 – 10.00
Training:
Link to Cost deployment
Training:
10.00 – 11.00 Plan SMED workshop Preparation for link to cost
Changeover
deployment: data Prepare 90-day plan
collection and analysis
11.00 – 12.00 Changeover deployment
12.00 – 13.00

15.00 – 16.00

16.00 – 17.00
Week Planning
17.00 – 18.00
55
WEEK 9
56
WEEK 9
OVERVIEW

Tools Related and Other Tasks
• KPI & Data (Prep) • Review changeover performance post SW deployment
• Factory Leadership Training (wk1) SMED • Train leadership and operators on SMED (including case study/pilot example)
• Line Daily Meeting (wk1) • Conduct SMED workshop
• PM BD SW (wk5)
• SMED (wk9)
57
WEEK 9
Tool/ Work
Process
Line Stops
deployment
SMED - Leadership and Operator Deployment LT, SMED team

Training SMED CBA, Relevant SMED case study/example PowerPoint 60 Mins
Training Team members
LT, SMED team

SMED - Deployment Deployment SMED CBA, SMED Checklist Leadership N/A 60 Mins
members

Activities

Team MGR, EM
Deployment
Team
Deployment
Team
Excel
checklist



Lead EM
Line Team
Lead
58
WEEK 9 DRUMBEAT
Tool/ Work
deployment
7.00 – 8.00
Line Daily Meeting
Scheduled stop
9.00 – 10.00
Training:
10.00 – 11.00
SMED
11.00 – 12.00 SMED Workshop SMED Workshop SMED Workshop

(time slot will vary (time slot will vary (time slot will vary
depending on changeover depending on changeover depending on changeover
12.00 – 13.00 timings) timings) timings)

15.00 – 16.00

16.00 – 17.00
Week Planning
17.00 – 18.00
59
WEEK 10
60
WEEK 10
OVERVIEW

• Continuous maturity increase of work processes
• Factory Strategy and Vision (Prep) Maturity of all work processes
• Preparation for self-sustaining organisation
• PM BD SW (wk5)
• SMED (wk9)
61
WEEK 10
Tool/ Work
Process
Line Stops
deployment

Activities

Team MGR, EM
Deployment
Team
Deployment
Team
Excel
checklist



Lead EM
Line Team
Lead
62
WEEK 10 DRUMBEAT
Tool/ Work
deployment
7.00 – 8.00
Line Daily Meeting
Scheduled stop
9.00 – 10.00
10.00 – 11.00
11.00 – 12.00
12.00 – 13.00

15.00 – 16.00

16.00 – 17.00
Week Planning
17.00 – 18.00
63
WEEK 11
64
WEEK 11
OVERVIEW

• PM BD SW (wk5)
• SMED (wk9)
65
WEEK 11
Tool/ Work
Process
Line Stops
deployment

Activities

Team MGR, EM
Deployment
Team
Deployment
Team
Excel
checklist



Lead EM
Line Team
Lead
66
WEEK 11 DRUMBEAT
Tool/ Work
deployment
7.00 – 8.00
Line Daily Meeting
Scheduled stop
9.00 – 10.00
10.00 – 11.00
11.00 – 12.00
12.00 – 13.00

15.00 – 16.00

16.00 – 17.00
Week Planning
17.00 – 18.00
67
WEEK 12
68
WEEK 12
OVERVIEW

• PM BD SW (wk5)
• SMED (wk9)
69
WEEK 12
Tool/ Work
Process
Line Stops
deployment

Activities

Team MGR, EM
Deployment
Team
Deployment
Team
Excel
checklist



Lead EM
Line Team
Lead
70
WEEK 12 DRUMBEAT
Tool/ Work
deployment
7.00 – 8.00
Line Daily Meeting
Scheduled stop
9.00 – 10.00
10.00 – 11.00
11.00 – 12.00
12.00 – 13.00

15.00 – 16.00

16.00 – 17.00
Week Planning
17.00 – 18.00
71
WEEK 13
72
WEEK 13
OVERVIEW

Preparation for continuation planning
• Factory Leadership Training (wk1) • Data collection for continuation plan
workshop
• PM BD SW (wk5)
• SMED (wk9)
73
WEEK 13
Tool/ Work
Process
Line Stops
deployment

Activities
Preparation for continuation Deployment

Working session Sample roadmaps Powerpoint 60 Mins WCM MGR, FD
planning team

Team MGR, EM
Deployment
Team
Deployment
Team
Excel
checklist



Lead EM
Line Team
Lead
74
WEEK 13 DRUMBEAT
Tool/ Work
deployment
7.00 – 8.00
Line Daily Meeting
Scheduled stop
9.00 – 10.00
10.00 – 11.00
Preparation for
11.00 – 12.00
continuation planning
12.00 – 13.00

15.00 – 16.00

16.00 – 17.00
Week Planning
17.00 – 18.00
75
WEEK 14
76
WEEK 14
OVERVIEW

Preparation for continuation planning
• Factory Leadership Training (wk1) • Data collection for continuation plan
workshop
• PM BD SW (wk5)
• SMED (wk9)
77
WEEK 14
Tool/ Work
Process
Line Stops
deployment

Activities
Preparation for continuation Deployment

Working session Sample roadmaps Powerpoint 60 Mins WCM MGR, FD
planning team

Team MGR, EM
Deployment
Team
Deployment
Team
Excel
checklist



Lead EM
Line Team
Lead
78
WEEK 14 DRUMBEAT
Tool/ Work
deployment
7.00 – 8.00
Line Daily Meeting
Scheduled stop
9.00 – 10.00
10.00 – 11.00
Preparation for
11.00 – 12.00
continuation planning
12.00 – 13.00

15.00 – 16.00

16.00 – 17.00
Week Planning
17.00 – 18.00
79
WEEK 15
80
WEEK 15
OVERVIEW

Continuation planning workshop • Continuation roadmap in place
• PM BD SW (wk5)
• SMED (wk9)
81
WEEK 15
Tool/ Work
Process
Line Stops
deployment

Activities
Factory
Continuation planning session Working session Sample roadmaps Powerpoint 60 Mins WCM MGR, FD
Director

Team MGR, EM
Deployment
Team
Deployment
Team
Excel
checklist



Lead EM
Line Team
Lead
82
WEEK 15 DRUMBEAT
Tool/ Work
deployment
7.00 – 8.00
Line Daily Meeting
Scheduled stop
9.00 – 10.00
10.00 – 11.00
Continuation Planning
11.00 – 12.00
Session
12.00 – 13.00

15.00 – 16.00

16.00 – 17.00
Week Planning
17.00 – 18.00
83
WEEK 16
84
WEEK 16
OVERVIEW

• PM BD SW (wk5)
• SMED (wk9)
85
WEEK 16
Tool/ Work
Process
Line Stops
deployment

Activities
Factory
Continuation planning session Working session Sample roadmaps Powerpoint 60 Mins WCM MGR, FD
Director

Team MGR, EM
Deployment
Team
Deployment
Team
Excel
checklist



Lead EM
Line Team
Lead
86
WEEK 16 DRUMBEAT
Tool/ Work
deployment
7.00 – 8.00
Line Daily Meeting
Scheduled stop
9.00 – 10.00
10.00 – 11.00
11.00 – 12.00
12.00 – 13.00

15.00 – 16.00

16.00 – 17.00
Week Planning
17.00 – 18.00
87
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WCM Blitz Playbook 20190705 v2

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WCM BLITZ

Playbook structure and

2 WCM Blitz approach overview

3 WCM Blitz principles

Title WCM Blitz Deployment Playbook

Version Number Modified By Modifications Made Date Modified Status

Current Best Practice Factory Work Pattern

Auxiliary Coaching Team 3

Health and Safety Standards

AM Standards - Line Settings and Scales

Daily Line Meeting

AM Standards - Clean, Inspect, Lubricate

Leadership Health Checks

PM Standards - Breakdown Elimination

PM Standards - Professional Maintenance

Changeover Standards and SMED

Link to Cost Deployment

Problem Solving (Kaizen, 5G, 5W 1H, Why Why etc.)

Unilever Leadership Capability

Key Work Process Tool Leadershi

1 Enhance focus on work processes

2 WCM is the way we manage operations, not additional work

5 Clear ownership for the completion of each task

8 Data will be the life blood of WCM Blitz

House Keeping Colour Coding Legend

• Current State Assessment (Prep) Work Process Related

Conduct Current State Deployment Shopfloor

Review current leadership FD, OM, EM, LT,

Review current state AM Pillar Deployment Working 120 AM Pillar Lead,

Tools Related and Other

Establish Line Team, coaching

Deployment Working 60 FM, EM, OM, WCM

Deployment Working 90 FD, OM, CI, WCM

Excel/physical PIL, WCM MGR,

Review relevant health and safety Working 60 EHS MGR, OM,

Current State Assessment

• Current State Assessment (Prep) Work Process Related

Daily Meeting Overview Trainings

AM, PM, FI Overview Training

8.00 – 9.00 Lien Daily Meeting Dry

Training: Preparation for Initial

Week Review and Next

• Current State Assessment (Prep) Work Process Related

Line Daily Meeting coaching – Deployment In-meeting

Scheduled stop Scheduled stop

Preparation reparation for Implement CIL Tracking

• Current State Assessment (Prep) Work Process Related

Tags Management Overview Deployment

Tools Related and Other

Deployment FD, OM, WCM

Communicate Leadership Working FD, WCM MGR,

Deployment FD, OM, WCM

Line Team LT, LTC, Extended

10.00 – 11.00 Training

Deploy weekly Tags

Week Review and Next

• Current State Assessment (Prep) Work Process Related

Tools Related and Other

Deployment FD, OM, WCM

Weekly Tags and Maintenance Weekly Maintenance Focused

Line Team LT, LTC, Extended

8.00 – 9.00 Leadership coaching zone

Week Review and Next

• Current State Assessment (Prep) Work Process Related