EEM Presentation Oct Audit Final

Safety, Hygiene &
Working Environment
Cost
Deployment
Focused
Improvement
Autonomous
Activity
Profissional
Maintenance
Quality
Customer Service/
Logistics
Early Equipment
Management Pillar
Pillar Leader: Fábio A. Rodrigues
People
Development
Environment
1
AGENDA
 Pillar Summary
Agenda
 KPIs & KAIs
Pillar Summary / KPIs &
KAIs
 Pillar Team
Pillar Team
 EEM Network EEM Net Work
MP information
 MP Information Evolution Evolution
Check List Evolution

 Check List Evolution
Pillar Master Plan
 DR System Projects:
- Hair 08
 Pillar Master Plan - Dante1 Kg
- Shadow 3L A06
 Projects Pillar Summary YTD
- Capacity Increase (Hair 08) Next Steps

- Dante 1 Kg Project
- Shadow 3L A06 Project
 Next Steps
2
EARLY EQUIPMENT MANAGEMENT
Vision
Be the best world class factory using the EEM tools to implement
new equipments that provide the best Safety and Quality designs,
delivering a low cost and high OEE, according to Unilever
Sustainable Living Plan.
Needs
Implement new technologies for easy operation, easy maintenance,

low LCC and low maintenance cost, accelerating vertical start up.
Objectives
Implement EEM 7 steps for pilot project – Nov 14

Improve Front Load Concept to achieve 80% until Step 3 – Dec 14
 Cover 70% of Capex with EEM 7 Steps – Dec 15
3
PILLAR SUMMARY – TARGETS
KPI
DESCRIPTION 2013 TARGET 2014 TARGET 2015 TARGET 2016
KAI
Agenda
OEE NEW
97% 97% 97,5% 98%
EQUIPMENTS Pillar Summary / KPIs
& KAIs
OLE NEW VARIANTS 65% 70% 75% 78%
Pillar Team
TOTAL PROJECT COST 100% 97% 95% 93% EEM Net Work
MP information
KPI 2 days – 4 weeks (by 2 days – 4 weeks (by 2 days – 4 weeks (by 2 days – 4 weeks (by Evolution
VERTICAL START UP
project classification) project classification) project classification) project classification)
Pillar Master Plan

SAFETY ZERO ACCIDENT ZERO ACCIDENT ZERO ACCIDENT ZERO ACCIDENT
Projects:
LEAD TIME WEEKS BY PROJECT WEEKS BY PROJECT WEEKS BY PROJECT WEEKS BY PROJECT - Hair 08
- Dante1 Kg
- Shadow 3L A06
PEOPLE INVOLVED
5% -30 10% - 60 15% - 90 17%- 100
(% -NUMBER) Pillar Summary YTD
Next Steps
% EEM 7 STEPS
25% 40% 70% 100%
CAPEX COVERED
KAI
MP INFOMATION 370 770 1.000 1.200
CHECK LIST
4.500 5.000 5.500 6.000
QUESTIONS
SCORE 1 3 3 4
4
EEM TEAM – RADAR CHART
EEM
QC
SAF
AM
Agenda

KAIs
Fábio A Rodrigues Lara Bomfim Sandro Chequito Pillar Team

Project Manager Project Coordinator Project Coordinator
EEM Leader EEM Specialist Pillar Member
EEM Net Work
MP information
Evolution
Pillar Master Plan

Target Projects:
Actual - Hair 08
Rafael Dertonio Wederson Luis Jéssica Zuerbine Wilson Moscattini Previous Audit - Dante1 Kg
Project Coordinator Project Coordinator Project Intern Project Coordinator - Shadow 3L A06
Pillar Member Pillar Member Pillar Member Pillar Member
Pillar Summary YTD

8 Engineers in
Next Steps
the team
Otávio Thomé Francisco Fernandes Natanael Scupinari Bruno Tambacha

Innovation Analyst Quality Coordnator SAF Coordinator Imanufacture Coordinator
Pillar Member Pillar Member Pillar Member Pillar Member
5
EEM TEAM – TRAINING
 Mapped the Radar Chart gaps to achieve the

All pillar members
target and planned a Training plan:
Specific members Agenda

KAIs
 Identified the needs by Pillar Team
Project to apply specific EEM Net Work

trainings: MP information
Evolution
 IC & RC Training: applied Check List Evolution
for Project Leader for Hair 08
Pillar Master Plan
(Wilson and Lara)
Projects:
 3D modeling Training: - Hair 08

applied for Project Leader and - Dante1 Kg
- Shadow 3L A06
one member of the Hair 08
Pillar Summary YTD
Project team (Wilson, Bruno
and Lara) Next Steps
 Flexibility Design Training:

scheduled for Project Leaders
from 123 Project, Rubik
Project and Flash Project
(Wilson, Sandro, Lara,
Wederson and Rafael)
6
EEM ACTIVITIES
• Individual EEM Material Study
• Weekly EEM Study Meeting – 1h

Agenda
EEM Material
• Weekly Pillar Meeting – 1h Pillar Summary / KPIs &
KAIs
Pillar Team
• New members training and integration
EEM Net Work
• Benchmark visits MP information

Evolution
Sections of study and meetings Check List Evolution

• WCM tools trainning
Pillar Master Plan
• Monthly Supply Leader apresentation – 1,5h Projects:
- Hair 08
- Dante1 Kg
• Weekly MP Info selection and approval - Shadow 3L A06
Pillar Summary YTD

• MP info Quality Review Data – once a quarter
Next Steps
Fiat benchmark Visit
• CL Review – once a quarter
• Cases of work
• Visitors reception to benchmark Vinhedo (Valinhos, Suape, Aguai,

Goiania and Cuernavaca)
7
Benchmark - visitors reception
EEM APPROACH: MANAGEMENT FLOW AND NET WORKING
Documents and
FI Standards QC Agenda

KAIs
Pillar Team
EEM Net Work
General MP information
Evolution
AM Data base
S&H Check List Evolution
MP Pillar Master Plan

Information
Data base Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD

PM ENV
Next Steps
CHECK LIST
8
MP INFORMATION MANAGEMENT FLOW
Problems People
Identification Knowledge
Agenda
Improvements All pillars are Pillar Summary / KPIs &

KAIs
Implementation responsible for this
Identification of
Pillar Team
MP Infos (EEM) EEM Net Work

Improvements MP information
registry (Kaizen) Evolution

Corrections
Pillar Master Plan

NO
Pre Projects:
FI team
Approval
MP Info - Hair 08
- Dante1 Kg
YES
Database - Shadow 3L A06
Pillar Summary YTD
Next Steps
Final Weekly meeting
NO Approval EEM, QC and S&H
Use in DR 1 for
Identification of Storage new projects
MP Infos (EEM)
9
MP INFORMATION MANAGEMENT FLOW
Registering and Consulting MP Information Excel Database

Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Seach by 4 key words Seach by equipment, Evolution
supplier and local Check List Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
10
MP INFORMATION GOALS
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
YTD: 697
11
CHECK LIST GOALS
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
YTD: 5.107
12
EEM CHECK LIST EVOLUTION AND TARGET
Front Loading
Agenda

KAIs
Pillar Team
Working on Front Loading
concept to achieve > 80% EEM Net Work
MP information
Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Evolution
Last audit: Today: Pillar Master Plan
Projects:
- Hair 08
Front Loading - Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
50% until Step 03 68% until Step 03

13
PILLAR MASTER PLAN
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD

169.3 Mi R$ Next Steps
(59.7 Mi Euros)
WCM Day
(July-2014) under EEM 7
Steps
14
PILLAR ROLL OUT PLAN – Q1 2015
Complexity
High Low
Vertical
Experience
startup
Scale Agenda
No Yes No Yes
2 weeks Pillar Summary / KPIs &

10 MEuro AA AA A B –1 KAIs
month
ca 1 – 2 Pillar Team
ca 1 – 5 MEuro AA A B C weeks
ca 1 EEM Net Work

ca 500,000Euro A B C C week
MP information
ca100,000Euro B C C C 2 days Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
FLASH PROJECT
Pillar Summary YTD
Next Steps
All “AA” projects covered by EEM

 All “A” projects covered by EEM
15
PROJECTS
 Pilot Project: Hair Process Capacity Increase (Hair 08):

Agenda
• New process plant Pillar Summary / KPIs &
• AA project KAIs
• Payback of 1,9 years Pillar Team
EEM Net Work
MP information
Evolution
 Packing line projects coming from CD Pillar: Check List Evolution
Pillar Master Plan

• Dante 1 Kg: Projects:
 650 K € of Hard Saving - Hair 08
 Payback of 2 years - Dante1 Kg
- Shadow 3L A06
 Volume internalization Pillar Summary YTD
Next Steps
• Shadow 3L A06 project:
 770 K€ of Hard Saving and 230 K € of Cost Avoidance
 Payback of 1,9 years
 Utilizing A06 spare capacity to bring volume
16
PILOT PROJECT
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
HAIR PROCESS CAPACITY INCREASE
17
1. PLANNING- BACKGROUND
HAIR-08
Spare
Capac 1
ity < 0
 As the volume is not liner
Agenda
0
815%
3,
% Pillar Summary / KPIs &
%
4
%
during the year, the installed KAIs
capacity is on the limit in high Pillar Team
volume months EEM Net Work
MP information
Evolution
Pillar Master Plan

HAIR-08 Projects:
- Hair 08
 The project will deliver a - Dante1 Kg
- Shadow 3L A06
new plant, with additional
Pillar Summary YTD
capacity of 30K Tons/year
Next Steps
18
HAIR PROCESS CAPACITY INCREASE REVIEW (LAST AUDIT)
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
19
EEM Project- HAIR CAPACITY INCREASE VINHEDO
Project Classification: AA ( R$ Agenda
25.7M) Pillar Summary / KPIs &

Time Line: Jun13 to Jun’14 KAIs
Production: Start on Jul´14 * Pillar Team
EEM Net Work

* Due to business decision, the
comissioning is postponed to October MP information
Evolution

Project Team
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Natanael
Pillar Summary YTD
Scupinari
SAF
Coordnator
Pillar Member
Project EEM
Next Steps
Leader AM
PM
R&D
SAF
QC
ENV
20
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
 Safety, quality and productivity - Shadow 3L A06
Pillar Summary YTD

improvements
 Focus on improvements Next Steps
compared with current plants

 Standardization
 Core design compliance
 Front loading concept application
21
7 STEPS APPROACH 1 2 3 4 5 6 7
Agenda

KAIs
Pillar Team
Trial Initial flow
EEM Net Work
production
MP information
Installation Step 7 Evolution
DR-7
Step 6 • Product quality
Manufacture • Operationability
Detailed Step 5 DR-6
Pillar Master Plan
• Maintainability
design • Debugging
DR-5 • Reliability Projects:
Step 4 • Debugging based
• Safety
on MP information • Equipment function - Hair 08
Basic - Dante1 Kg
Step 3 DR-4 • Equipment capacity
design • Research
- Shadow 3L A06
Planning • Confirmation of Pillar Summary YTD
machine function
DR-3
Step 2 • Research
and accuracy
Next Steps
DR-2 • MP project
Step 1 • Establishment of • Planning for QA based
project goals on 5 conditions
DR-1 • LCC or LCP • Flexibility
• Purpose of investment • Equipment function • LCC planning
• Needs • Equipment capacity • Safety planning
• Equipment function • Quality level
• Profitability checking • Lay-out
• Time of development • Visualization
• Time of development
22
INSTALLATION 1 2 3 4 5 6 7
Safety Quality
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
The entry on installation area is The entire area is well isolated,
restricted. There is a safety preventing the escape of dust
Pillar Master Plan
technician in charge to this work. into the factory
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD

81.380 man-hour-
Next Steps
worked with no
incidents
23
1 2 3 4 5 6 7
INSTALLATION
Planned Installed
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
Planned Installed - Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
24
1 2 3 4 5 6 7
INSTALLATION
Planned Installed
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
Planned Installed - Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
25
1 2 3 4 5 6 7
IMPROVEMENTS
CURRENT PLANTS
• Tool needed
• Not hygienic design, and no perfect seal Agenda
• 4 minutes disassembling Pillar Summary / KPIs &

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
HAIR 08 IMPROVEMENT - Hair 08

- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
Tri clamp connection, perfect seal and
support for filter cleaning:
 No tool needed
 Hygienic model
 1 minute disassembling
26
IMPROVEMENTS 1 2 3 4 5 6 7
CURRENT PLANTS
Agenda

KAIs
• Open elevator allows the
accumulation of dirt Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
HAIR 08 IMPROVEMENT
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
The elevator is closed:

 Prevent dirty accumulation
 Safety improvement
27
1 2 3 4 5 6 7
INSTALLATION – IMPROVEMENTS
CURRENT PLANTS
Agenda
 Possibility of contact with moving Pillar Summary / KPIs &

KAIs
parts of the pumps  Safety risks
Pillar Team
 Lack of visual inspection possibility
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
HAIR 08 IMPROVEMENT - Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD

 Safety risk eliminated
Next Steps
 Visual control and inspection contemplated
 Standardization
 One check point added on check list
 One Kaizen generated
28
1 2 3 4 5 6 7
INSTALLATION
WCM Material
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD

 Easy inspection and identification
Next Steps
 Easy visualization of the materials flow
29
INSTALLATION 1 2 3 4 5 6 7
WCM Material
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
 Visual control of working ranges

 Visualization at operator eye height
30
INSTALLATION
1 2 3 4 5 6 7
WCM Material
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
Operational valves Maintenance valves

green red
 Different colors of valves for operational and maintenance to prevent human errors
 Indication of normal conditions to prevent human errors
31
COLLECTING DATA TO GENERATE
1 2 3 4 5 6 7
MACHINE LEDGER
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
 Data recieved from

the supplier and shared
with PM Pillar
32
DESIGN REVIEW 5 - CHECK LIST STEP 5 1 2 3 4 5 6 7
546 Questions • 10 opened problems

422 Checkpoints applied
Agenda
12 Checkpoints added
• 10 closed problems
KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
From this modifications Projects:

2 items could be - Hair 08
discovered steps before - Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
33
1 2 3 4 5 6 7
NUMBER OF MODIFICATIONS BY STEP
 BEFORE: The Ystral hose for suction  AFTER: A new hose was made,
was heavy and there was no support ergonomically correct with a support
contemplated
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
 Cost of modification: R$ 2.205,00 - Hair 08

- Dante1 Kg
This point could be detected earlier. 03 front loading concept questions added - Shadow 3L A06
on check list: Pillar Summary YTD

1.The supplier shared the weight of the equipment/pieces/accessories? STEP 02 Next Steps
2. There is opportunities with the supplier to reduce the weight of
equipments/parts/accessories? STEP 02
3. The accessories for the equipment have heavy parts that the operators have to
handle? STEP 02
4. The accessories for the equipments have projected support? STEP 02
 One Kaizen generated 34

Agenda

KAIs
Pillar Team
Trial Initial flow
EEM Net Work
production
MP information
Installation Step 7 Evolution
Step 6 DR-7 Check List Evolution
• Product quality
Pillar Master Plan
• Maintainability
• Safety
Basic - Dante1 Kg
design • Research
- Shadow 3L A06
machine function
DR-3
Step 2 • Research
and accuracy
Next Steps
DR-2 • MP project
35
1 2 3 4 5 6 7
ENGINEERING TEST SCHEDULE
Engineering day by day schedule

Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
 Point to point tests, valves, pumps, agitation
Pillar Summary YTD
speeds and sensors
 All raw materials dosing system tested Next Steps
 All routines tested DETAIL
 All software tested

 Software for the historic of dosages and
failure reports tested
36
1 2 3 4 5 6 7
PROCESS ENGINEERING TESTS SCHEDULE
Process day by day schedule

Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
 All formula portfolio

validation
38
OPERATORS TRAINING 1 2 3 4 5 6 7
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
 All operators trained: Pillar Summary YTD
 New system of historic and Next Steps
traceability
 Software for collecting data
automatically and generation of
quality reports
39
DESIGN REVIEW 6 - CHECK LIST STEP 6 1 2 3 4 5 6 7
523 Questions • 08 opened problems

Agenda
8 Checkpoints added
• 08 closed problems
KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
The 2 items could Projects:

be discovered steps - Hair 08
before - Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
40
NUMBER OF MODIFICATIONS BY STEP 1 2 3 4 5 6 7
 The bottom of exhauster on/off system  The button to turn on/off was replaced
was on different floor by an automated system by PLC (MMI).
 NVAA added  No NVAA involved
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
 Cost of modification: no cost (included in automation monitoring for tests and - Dante1 Kg
- Shadow 3L A06
commissioning) Pillar Summary YTD
This point could be detected earlier. 02 front loading concept questions added Next Steps
on check list:
1. The equipments layout of commands was planned to avoid NVAA on turn on/off?
STEP 01
2. Is there any physical command on equipment that could be replaced by automation
command on IHM? STEP 03
 One Kaizen generated 41

STATISTICS 1 2 3 4 5 6 7
No cost Agenda
Total cost of modifications :
less than 0,01% of the KAIs
project total cost Pillar Team
EEM Net Work
MP information
Evolution
No cost Check List Evolution
R$ 1.300,00 Pillar Master Plan
Projects:
R$ 2.205,00
- Hair 08
No cost - Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
Number of modifications
This items generated 37 early
Items that could be discovered steps before questions on front loading concept
42
DATABOOKS/MANUALS/MACHINE LEDGERS 1 2 3 4 5 6 7
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
 Data sheet, manual and documentation of the tanks, pumps, valves, Next Steps
sensors and instruments;
 Machine ledger of the main equipments
 Calibration certificates
 Inox Material rastreability certificate;
 Project documentation: fluxograms, mechanical drawings, electrical
charts, 3D model.
43
1 2 3 4 5 6 7
HAIR 8 INAUGURATION
FERNANDO FERNANDEZ – PRESIDENT OF UNILEVER BRASIL
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
44
NEXT STEPS
 Finish the Commissioning and Ramp Up period

Agenda
 Apply DR 07 Pillar Summary / KPIs &
KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
45
PROJECTS

Agenda
• AA project KAIs
EEM Net Work
MP information
Evolution
Pillar Master Plan

- Shadow 3L A06
Next Steps
46
DANTE 1 KG PROJECT
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
New format - Line S03

47
BACKGROUND – COMPANY STRATEGIES
(1) The results of marketing
(2) What is the key of success?
(3) Gap between the ideal status and actual status? Agenda
(4) Product strategies Pillar Summary / KPIs &

KAIs
(5) Manufacturing/sales strategies
Pillar Team
(6) Product investigation
EEM Net Work
MP information
Evolution
(1) Treatment Cream market in Brazil is growing very fast
(2) Seda and Tresemme were launched in 2011 and already
Pillar Master Plan
represents more than a half of the treatment creams share in
Projects:
Brazil
- Hair 08
(3) Currently this format is produced in a co-maker (Provider). The - Dante1 Kg
- Shadow 3L A06
key is internalize this product, because the costs are high in a co-
Pillar Summary YTD
maker. Year 01 Year 02 Year 03 Year 04 Next Steps
(4) The volume forecast is tons 960 2.960 4.649 4.649
(5) The internalization will invest a 0,6 Mi €, internalizing 960 tons

on first year. The saving is 650 K Euros
(6) S03 produces a similar package in 400 g format
48
PROJECT CLASSIFICATION
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
49
EEM - 7 STEPS
EEM Project- PROJECT DANTE 1kg
Agenda
Project Classification: C (1.7 Mi R$) Pillar Summary / KPIs &
Time Line: Fev’14 to Sep’14 KAIs
Production: Start on Oct´14 Pillar Team
EEM Net Work

Project Team MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Project EEM
Leader AM Pillar Summary YTD
PM Next Steps
R&D
SAF
QC
ENV
50
Agenda

KAIs
Initial flow
Pillar Team
Trial
EEM Net Work
production
Step 7 MP information
DR-7 Evolution
Installation • Product quality
Step 6 • Operationability Check List Evolution
Manufacture • Maintainability
Detailed Step 5 DR-6 • Reliability Pillar Master Plan
• Debugging • Safety
design Projects:
DR-5 • Equipment function
Step 4 • Debugging based • Equipment capacity
on MP information - Hair 08
Basic - Dante1 Kg
Step 3 DR-4
design • Research
- Shadow 3L A06
machine function
Step 2 DR-3 and accuracy
• Research Next Steps
DR-2 • MP project
51
TIME SCHEDULE 1 2 3 4 5 6 7
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
Step 1
Step 2
Step 3
Step 4
Step 5
Step 6
Step 7
1 2 3 4 5 6 7
OEE DETERMINATION
 S03 Losses extratification/Risk analisys per equipment
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
53
OEE DETERMINATION
1 2 3 4 5 6 7
 Aligned with CD Pilar, the

OEE determination was Agenda
based on the main losses Pillar Summary / KPIs &
currently faced, and an KAIs
incremental of improvement Pillar Team
EEM Net Work
MP information
Evolution
Current OLE S03 53% Check List Evolution
Pillar Master Plan
Projects:
 Unscrambler selectors
- Hair 08
improvements - Dante1 Kg
- Shadow 3L A06
 Change over reduction
Pillar Summary YTD
 Time of adjustments Next Steps

reduction
OLE Target Dante 1 Kg 70%
54
LAYOUT 1 2 3 4 5 6 7
S03 Layout: kits for current equipments
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
55
1 2 3 4 5 6 7
WHAT CHANGES?
• 1kg Bottles
• Labels and back labels
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
 Learning from Issey Project:

possibility of using same caps for
current 400 g format
56
1 2 3 4 5 6 7
CLIENT REQUIREMENTS
Agenda

KAIs
Perspectives from: Pillar Team
Safety
Manufacturing EEM Net Work
Regional Engineering MP information
Quality Evolution
Maintenance
Clients requirements
Pillar Master Plan
1)Safety/Quality Projects:
• Zero incidents and accidents
• Zero critical defcts of quality according to the book - Hair 08
- Dante1 Kg
- Shadow 3L A06
2)OEE Pillar Summary YTD

Project • Achieve the agreed speed
Next Steps
Requirements • Minimize Change over impacts
• Reduce the time of ajustments
(few examples)
3) Delivery
• Implement the project on time agreed with Unilever business
• Keep the standards of the new change parts
• Introduce new technologies of the change parts to minimize the
time of change over for Autonomous Maintenance Pillar
request
57
1 2 3 4 5 6 7
MP INFORMATION USED
Agenda

KAIs
Pillar Team
EEM Net Work

92 MP information
used by EEM Team
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
58
1 2 3 4 5 6 7
DESIGN REVIEW 1 - IMPROVEMENTS
MP Functional Design
Agenda
Safety Reliability Maintenance Autonomous Operation Quality
Maintenannce Pillar Summary / KPIs &
KAIs
Pillar Team
Unic chuck Unic kits for all S03 formats EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
 Don’t need to change the kits

 Saving 470 tons per year
 Reduction of 39 minutes per change
59
1 2 3 4 5 6 7
 BEFORE: problem on cam (quality AFTER: New system will be installed

check) to add new recipes, very – more accurate, increasing Agenda
often stops on the system realiability and traceability
KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
 30 minutes per shift of

 Reduction of 30 minutes per shift
adjustments
 Lack of traceability
 Saving R$ 72.000,00 per year
 Save parameters historic  traceability
60
DR REVIEW AND NUMBER OF MODIFICATIONS
1 2 3 4 5 6 7
518 Questions •35 opened problems Agenda

474 Checkpoints applied •35 closed problems Pillar Summary / KPIs &
KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
61
Agenda

KAIs
Pillar Team
Trial Initial flow
EEM Net Work
production
MP information
Step 7 Evolution
Installation
DR-7
Pillar Master Plan
• Maintainability
• Safety
Basic - Dante1 Kg
design • Research
- Shadow 3L A06
machine function
DR-2 • MP project
62
1 2 3 4 5 6 7
DETERMINATION OF PERFORMANCE
Planned Ramp Up Curve
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
Safety accidents - zero

Quality defects - zero
OLE - 70%
Speed – 72bpm
Number of cases – 52.186 63
1 2 3 4 5 6 7
DETERMINATION OF QUALITY
Labels Box Palletization

Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Jars
Pillar Summary YTD
Next Steps
64
1 2 3 4 5 6 7
SUPPLIER REQUIREMENTS
Agenda

KAIs
Pillar Team
EEM Net Work

New screws profile
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD

Grippers Suppliers requirements: Next Steps
 Specifications agreed
 Sent all data required to receive
Machine Ledger
 Scheduled all progress follow up
activities
Funnel 65
1 2 3 4 5 6 7
DESIGN REVIEW 2 – IMPROVEMENTS
 BEFORE: The change part of Cermex

machine is heavy and need to AFTER: Develop a new system.
disassembling in opposite sides at the It´s safe and ergonomically better Agenda
same time
KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
Safety design
 Unsafe design  Reduction of 7 minutes per change
 Ergonomically incorrect  Ergonomically correct
 15 minutes for disassembling  01 check point added on CL
 01 Quick Kaizen generated
66
DR REVIEW AND NUMBER OF MODIFICATIONS
1 2 3 4 5 6 7
1004 Questions •25 opened problems

883 Checkpoints applied •25 closed problems
Agenda

13 Checkpoints added KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
From this Projects:

modifications 4 items
- Hair 08
could be discovered - Dante1 Kg
- Shadow 3L A06
steps before
Pillar Summary YTD
Next Steps
67
DESIGN REVIEW 2 - MODIFICATIONS 1 2 3 4 5 6 7
 BEFORE: The current bottles is smaller than  AFTER: The team studied the whole bottle
the new ones. The project contemplate all trajectory and made corrections in the current
guides change guides  less changes, less adjustments and
savings Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
 This study generated a cost avoidance of R$ 70.000,00 (new guides) Next Steps
 Reduction of 7 minutes per change

This point could be detected earlier. 02 front loading concept questions
added on check list:
1. New guides are needed? It´s possible to make just critical parts? STEP 01
2. To test the need of change guides, a test with the new bottle was made on the line?
STEP 01
68
Agenda

KAIs
Pillar Team
Trial Initial flow
EEM Net Work
production
MP information
Step 7 Evolution
Installation
DR-7
Pillar Master Plan
• Maintainability
• Safety
Basic - Dante1 Kg
design • Research
- Shadow 3L A06
machine function
DR-2 • MP project
69
DESIGN REVIEW 3 – IMPROVEMENTS 1 2 3 4 5 6 7
 BEFORE: During the cap placing, the AFTER: Projected a silicone profile
bottles spins with the chucks, and it which keeps the bottle fixed during
causes wrong closing the cap placing Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
 Quality Issues  Quality compliance

 Losses of R$ 90.000,00 per year  Saving of R$ 90.000,00 per year
70
1912 Questions • 23 opened problems Agenda

• 23 closed problems Pillar Summary / KPIs &
KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
From this - Hair 08

- Dante1 Kg
modifications 3 items - Shadow 3L A06
could be discovered
Pillar Summary YTD
steps before
Next Steps
71
1 2 3 4 5 6 7
DESIGN REVIEW 3 - MODIFICATIONS
 BEFORE: There is a risk of non rejection of  AFTER: Projected a different sensor and
the bottles in wrong position point of compressed air to reject the wrong
positioned bottles
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
 This point could be detected earlier. 02 front loading concept questions

1. The bottle design allows blind spots to the sensors? STEP 02
2. A test to detect blind spots for the sensors was made? STEP 02
72
Agenda

KAIs
Pillar Team
Trial Initial flow
EEM Net Work
production
MP information
Step 7 Evolution
Installation
DR-7
Pillar Master Plan
• Maintainability
• Safety
Basic - Dante1 Kg
design • Research
- Shadow 3L A06
machine function
DR-2 • MP project
73
1 2 3 4 5 6 7
PROTOTYPE
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
Chuck Capper star

entrance
74
1 2 3 4 5 6 7
PRE-DELIVERY INSPECTION
• Unscrambler Kits
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
Missing surface Necessary Missing

finishing Machining Screw
75
1 2 3 4 5 6 7
PRE-DELIVERY INSPECTION
• Screw System Kits
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
Multi format chuck system

76
DESIGN REVIEW 4 – IMPROVEMENTS 1 2 3 4 5 6 7
 BEFORE: Compressed air point AFTER: Installed a sensor to turn on

working uninterruptedly to reject the compressed air point only when
wrong caps an incorrect position cap is detected Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
 Losses on compressed air Noise reduction to 15 minutes per

 Continuous noise 480 minutes per shift
shift. Less air compressed consumption
Less energy consumption
77

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
From this - Hair 08

- Dante1 Kg
modifications 1 item - Shadow 3L A06
could be discovered
Pillar Summary YTD
steps before
Next Steps
78
 BEFORE: The buffer was design to 400 g  AFTER: The 1 Kg format is bigger, so there
format is a need of increase the height of the
Unscrambler to avoid lack of bottles  Agenda
Improvement of visual control
KAIs
Pillar Team
EEM Net Work
MP information
+ 200mm Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
 Cost of modification: R$ 7.300,00 Next Steps

1. The size of the bottle impact on the buffers? (Unscrambler) STEP 02
2. The size of the caps impact on the buffers? (Cap unscrambler) STEP 02
3. The impact on the size of bottles/caps was contemplated in order to avoid lack of
material? STEP 02
79
Agenda

KAIs
Pillar Team
Trial Initial flow
EEM Net Work
production
MP information
Step 7 Evolution
Installation
DR-7
Pillar Master Plan
• Maintainability
• Safety
Basic - Dante1 Kg
design • Research
- Shadow 3L A06
machine function
DR-2 • MP project
80
CURRENT LINE TAGS OPPENED 1 2 3 4 5 6 7
 Made a survey in all line tags and addressed all actions before the tests
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
81
1 2 3 4 5 6 7
AFTER: Developed one single

 BEFORE: Different chucks and
chuck compatible with all formats,
kits for each format Agenda
and quick change kits
KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD

Achieved zero
Next Steps
for chucks
change over
18 minutes to change all chucks Reduction for “zero”

 Saving of R$ 59.934,60 per year
82
1 2 3 4 5 6 7
 BEFORE: each format have AFTER: Harmonization of the stars

specifics stars wheels, and the wheels entrance and quick
assmbling are not easy to change assemblings Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD

Achieved zero
Next Steps
for star wheel
change over
21 minutes to change the stars  Reduction for “zero”

 Saving of R$ 130.766,40 per year
83
1 2 3 4 5 6 7

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
From this
modifications 1 item - Hair 08
- Dante1 Kg
could be discovered - Shadow 3L A06
steps before
Pillar Summary YTD
Next Steps
84
 BEFORE: Collisions between photocell and  AFTER: Decrease of height (20 mm) of
new guide extensions on label machine entrance guide on the label machine
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
 Investment of R$ 2.300,00 Next Steps

1. A test with the new bottle was made to check the height of the line components? Simple
test running on bottle to see if there is some colision between bottles and sensors?
STEP 03
85
Agenda

KAIs
Pillar Team
Trial Initial flow
EEM Net Work
production
MP information
Step 7 Evolution
Installation
DR-7
Pillar Master Plan
• Maintainability
• Safety
Basic - Dante1 Kg
design • Research
- Shadow 3L A06
machine function
DR-2 • MP project
86
1 2 3 4 5 6 7
INTEGRATED TESTS RESULTS
 Average time of non stop current line: 10 minutes
 In test period, there is no commitment of volume for sale
Agenda
 All equipments worked more than 33 minutes without stoppage Pillar Summary / KPIs &
KAIs
 Line speed: 72 bottles/min. Pillar Team
 16.000 cases produced for sale EEM Net Work
 100% of actions solved MP information
 Quality issues solved Evolution
Pillar Master Plan
Example of quality issue solved: not Projects:

well closed caps. Adjustments on
- Hair 08
the capper chucks parameters - Dante1 Kg
- Shadow 3L A06
solved the problem
Pillar Summary YTD
Next Steps
Example of quality issue solved:

back label with scratch. Adjustments
in the speed of the screw in case
packer solved the problem
87
1 2 3 4 5 6 7

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
This item could be - Hair 08

- Dante1 Kg
discovered steps - Shadow 3L A06
before
Pillar Summary YTD
Next Steps
88
1 2 3 4 5 6 7
DESIGN REVIEW 6 - MODIFICATIONS
 BEFORE: Compressed air point rejecting  AFTER: Increase of levels of adjustments on
correct position of bottles on Unscrambler the machine, and added a visual control
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
 Investment of R$ 300,00 - Shadow 3L A06
 This point could be detected earlier. 01 front loading concept questions Pillar Summary YTD
added on check list: Next Steps
1. In terms of visual control improvement, a pre work on the line was made? (raising
weakness, opportunities and good practices) STEP 02
2. Considering the new bottles size, a general review on the line was done focused on the
differences on height? STEP 02
3. The existent levels of adjustments are enough to the new format? Is there any physical
limiting of height or position for sensors? STEP 04
89
STATISTICS 1 2 3 4 5 6 7
Agenda
No cost Total cost of
modifications : 0,6% of KAIs
the project total cost Pillar Team
EEM Net Work
MP information
Evolution
No cost
R$ 2.300,00 Projects:
- Hair 08
R$ 300 - Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
90
1 2 3 4 5 6 7
STATISTICS – CHANGE OVER REDUCTION
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
Reduction of
75 minutes
Before: 207 minutes After: 132 minutes
91
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
 Machine ledger of the kits
 Calibration certificates;
 Manuals of machines;
 Project documentation: layouts and 3 D modeling;
 Technical drowning of the kits and assembling.
92
NEXT STEPS FOR DANTE 1 KG CASE
• Finish DR 06
Agenda
• Apply DR 07 Pillar Summary / KPIs &

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
93
PROJECTS

Agenda
• AA project KAIs
EEM Net Work
MP information
Evolution
Pillar Master Plan

- Shadow 3L A06
Next Steps
94
SHADOW 3L LINE A06 PROJECT
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
New format 3L in line A06
95
BACKGROUND – COMPANY STRATEGIES
(1) The results of marketing
(2) What is the key of success?
(3) Gap between the ideal status and actual status?
(4) Product strategies Agenda
(5) Manufacturing/sales strategies Pillar Summary / KPIs &
(6) Product investigation KAIs
Pillar Team
(1) The market is facing an increasing sales volume on diluted EEM Net Work
(2) The key is to increase the production of 3L diluted on Vinhedo MP information

Evolution
(3) The line which produce 3L don't have enough capacity to increase Check List Evolution
(4) Due to forecasts, in 2014 there is a need of 17% more volume to Pillar Master Plan
produce Projects:
(5) The strategy is to use the spare capacity on A06 to bring the volume of - Hair 08
3L format. The Project will give a Hard Saving of 770 K Euros and a - Dante1 Kg
- Shadow 3L A06
Cost Avoidance of 230 K Euros Pillar Summary YTD
Next Steps
(6) To produce in A06 is necessary invest on kits for 3L format for current
equipments
96
PROJECT CLASSIFICATION
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
97
ACTIVITIES OVERVIEW
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
98
1 2 3 4 5 6 7
 CURRENT LINES: the guides 3L FORMAT A06: developed new

have two fixation points and the guides with quick assembling and
material scratches the bottles centralization on the adjustments Agenda
points
KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
 45 minutes to change
 Scratches on bottles  5 minutes to change
 No scratches on bottles
99
1 2 3 4 5 6 7
TESTS RESULTS
 Average time of non stop current line: 10 minutes

 In test period, there is no commitment of volume for sale Agenda

KAIs
 All equipments worked more than 52 minutes without stoppage Pillar Team
 Line speed: 60 bottles/min. EEM Net Work
 34.874 cases produced for sale MP information
 Quality issues solved Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
Example of quality issue

solved: wrinkles on the
label. Adjustments on the
label machine were done.
100
SAFETY RESULTS
1 2 3 4 5 6 7
Agenda

KAIs
Pillar Team
EEM Net Work

Zero safety MP information
accidents Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
101
1 2 3 4 5 6 7
QUALITY RESULTS
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Zero Quality Check List Evolution
Defects
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
102
1 2 3 4 5 6 7
PRODUCTIVITY RESULTS
Target OLE - 70%  Project Shadow 3L OLE – 72% Agenda

KAIs
Productivity Shadow 3L A06 Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
Planned cases
delivered on time
103
NON STOP LINE 1 2 3 4 5 6 7
Agenda
Record after ramp up period Pillar Summary / KPIs &

KAIs
Pillar Team
EEM Net Work

Record during commissioning
MP information
period Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Next Steps
Project start
Record of production during the commissioning and Ramp Up

New
. record after ramp-up period;
Improvement on line eficiency and productivity after project implementation;
104
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
 Machine ledger of the kits

 Calibration certificates;
 Manuals of machines;
 Project documentation: layouts and 3 D modeling;
 Technical drowning of the kits and assembling.
105
Agenda

KAIs
Pillar Team
Trial Initial flow
EEM Net Work
production
MP information
Step 7 Evolution
Installation
Step 6 DR-7 Check List Evolution
• Product quality
Pillar Master Plan
• Maintainability
• Safety
Basic - Dante1 Kg
design • Research
- Shadow 3L A06
machine function
DR-2 • MP project
106
1 2 3 4 5 6 7
STRENGHTS, WEAKNESSES, OPPORTUNITIES
AND THREATS
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
• 17 Check point
added on CL
107
1 2 3 4 5 6 7
OPERATION FEED BACK
POSITIVE POINTS
Agenda

KAIs
New guides with Pillar Team
Change
fast
Great teamover
adjustments
work EEM Net Work
reduction time
which fit to all MP information
Evolution
formats Check List Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Well done
Cases
Three delivered
records
Pillar Summary YTD
adressing of of
on time
production!!
Next Steps
existent line tags
108
1 2 3 4 5 6 7
OPERATION FEED BACK
POINTS FOR IMPROVEMENT
Agenda

KAIs
Pillar Team
EEM Net Work
Serac support MP information

Evolution
need to improve Check List Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
109
CURRENT OLE AFTER PROJECT DELIVER 1 2 3 4 5 6 7
82% OLE
achieved!!
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
OLE TARGET
First Record  18.406 cases delivered

 Second Record  18.922 cases delivered
 Third Record  21.600 cases delivered 110
1 2 3 4 5 6 7
Agenda
No cost Total cost of
modifications : 0,3 % of KAIs
No cost the project total cost Pillar Team
EEM Net Work
R$ 3.200,00 MP information
Evolution
Projects:
R$ 1.050,00
- Hair 08
No cost - Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
111
SAVINGS LINKED WITH CD PILLAR
Agenda
Dante 1 Kg Project Pillar Summary / KPIs &

KAIs
Shadow 3L A06 Project
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
112
PILLAR SUMMARY – TARGETS
KPI/KAI DESCRIPTION TARGET 2014 YTD 2014
OEE NEW EQUIPMENTS 97% 98% Agenda

OLE NEW VARIANTS 70% 82% KAIs
Pillar Team
TOTAL PROJECT COST 97% 95%
EEM Net Work
KPI 2 days – 4 weeks (by project 2 days – 4 weeks (by project
VERTICAL START UP MP information
classification) classification) Evolution
SAFETY ZERO ACCIDENT ZERO ACCIDENT Check List Evolution
Pillar Master Plan
LEAD TIME WEEKS BY PROJECT WEEKS BY PROJECT Projects:
- Hair 08
PEOPLE INVOLVED (% - - Dante1 Kg
10% - 60 8,5% - 51 - Shadow 3L A06
NUMBER)
Pillar Summary YTD
% EEM 7 STEPS
40% 41% Next Steps
KAI CAPEX COVERED
MP INFOMATION 770 697
CHECK LIST QUESTIONS 5.000 5.107
SCORE 3 2
113
NEXT STEPS
 Finish the Commissioning and Ramp Up period for Hair 08 Project; Agenda

KAIs
 Apply DR 07 for Hair 08 Project; Pillar Team
EEM Net Work

 Finish DR 06 for Dante 1 Kg Project; MP information
Evolution
 Apply DR 07 for Dante 1 Kg Project; Check List Evolution
Pillar Master Plan
 Apply EEM 7 Steps for Serendipty, 123, Rubik and Flash Projects; Projects:
- Hair 08
- Dante1 Kg
 Develop Cost Deployment for EEM; - Shadow 3L A06
Pillar Summary YTD
 Work with PM Pillar to generate the Machine Ledger for new equipments Next Steps
114
Thank you!
LCC 1 2 3 4 5 6 7
WHERE:
i = Discount rate
t = Equipment life in years Agenda
IC = Equipment cost + Spare Parts
RC = Maintenance + Utilities KAIs
Pillar Team
EEM Net Work

Mixers and Pre-mixers MP information
Evolution
Core Design Check List Evolution
Compliance
(Global Team)
DR System
Pillar Master Plan
Supplier 2 was Data collection from

Project
chosen due to
Next Steps
existing mixers and pre-
a lower LCC mixers
Essencial parts:
The equipments generate
transformation Drawings sent to local
suppliers for quotation
116
PROF. YAMASHINA COMMENTS
1. 6 months to install equipments is too long. We must use a very detailed project
activities schedule to really understand deeper and get shorter time overall;
2. Use PFMEA / FMEA tool to prevent quality issues in the relevant projects.
3. Improve visual control in the Hair 8 project. Go deeper on Visual Control of Prof
Yamashina´s material and application.
4. Standardize the components in the installation to minimize maintenance effort.
5. In a Front Loading concept, the questions should be concentrated until Step 03

(We should anticipate suitable questions of Steps 04, 05, 06 and 07);
117
1 2 3 4 5 6 7
 CURRENT LINES: to remove
3L FORMAT A06: installed a device
the change parts on case packer
to Lock Out and Tag Out the
there was a residual energy after
pneumatic energy on the equipment Agenda
the open door
Prof. Yamashina
comments

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Hair Process Capacity

Increase Project
Dante 1kg Project
Shadow 3L A06
Project
Next Steps
 Safety risk  No safety risk

 Compliance with LOTO parameters
118
CURRENT OLE AFTER PROJECT DELIVER 1 2 3 4 5 6 7
Agenda

KAIs
Pillar Team
EEM Net Work
MP information
Evolution
Pillar Master Plan
Projects:
- Hair 08
- Dante1 Kg
- Shadow 3L A06
Pillar Summary YTD
Next Steps
OLE TARGET 119

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Safety, Hygiene &

Pillar Leader: Fábio A. Rodrigues

 EEM Network EEM Net Work

Check List Evolution

 Projects Pillar Summary YTD

- Capacity Increase (Hair 08) Next Steps

Implement new technologies for easy operation, easy maintenance,

Implement EEM 7 steps for pilot project – Nov 14

Pillar Master Plan

Pillar Summary / KPIs &

Fábio A Rodrigues Lara Bomfim Sandro Chequito Pillar Team

Check List Evolution

Pillar Master Plan

Pillar Summary YTD

Otávio Thomé Francisco Fernandes Natanael Scupinari Bruno Tambacha

 Mapped the Radar Chart gaps to achieve the

Pillar Summary / KPIs &

 Identified the needs by Pillar Team

Project to apply specific EEM Net Work

 3D modeling Training: - Hair 08

 Flexibility Design Training:

• Weekly EEM Study Meeting – 1h

• Benchmark visits MP information

Sections of study and meetings Check List Evolution

• Monthly Supply Leader apresentation – 1,5h Projects:

Pillar Summary YTD

• Visitors reception to benchmark Vinhedo (Valinhos, Suape, Aguai,

Pillar Summary / KPIs &

EEM Net Work

MP Pillar Master Plan

Pillar Summary YTD

Improvements All pillars are Pillar Summary / KPIs &

MP Infos (EEM) EEM Net Work

Check List Evolution

Pillar Master Plan

Pillar Summary YTD

Registering and Consulting MP Information Excel Database

Pillar Summary / KPIs &

EEM Net Work

supplier and local Check List Evolution

Pillar Master Plan

Pillar Summary YTD

Pillar Summary / KPIs &

EEM Net Work

Check List Evolution

Pillar Master Plan

Pillar Summary YTD

Pillar Summary / KPIs &

EEM Net Work

Check List Evolution

Pillar Master Plan

Pillar Summary YTD

Pillar Summary / KPIs &

Check List Evolution

Last audit: Today: Pillar Master Plan

Pillar Summary YTD

50% until Step 03 68% until Step 03

Pillar Summary / KPIs &

EEM Net Work

Check List Evolution

Pillar Master Plan

Pillar Summary YTD

2 weeks Pillar Summary / KPIs &