Princes Limited

An Application of Autonomous Maintenance

Our History
Princes’ heritage dates back to 1880 when
it was established as a fish importing
business
in Liverpool, the city where our international
headquarters are still located today.

The iconic Princes brand was first established

in 1900 and is familiar to millions of
consumers

As a wholly-owned subsidiary of Mitsubishi

Corporation since 1989, Princes has
accelerated its development over the last two
decades by completing 22 mergers and
acquisitions that have added scale and
expertise to the business.
 Netherlands
Princes Locations Office Drink Site Food Site Oil Site Princes Foods B.V.

Glasgow Liverpool Head Office

France
Princes Foods B.V.
Eden Valley Wisbech Princes France
opened Jan 2016

Poland
Princes Polska
Szamotuly
Bradford Long Sutton

Italy
Manchester Chichester Angri

Cardiff Erith Foggia

Church Stretton Belvedere Mauritius x 2

Princes Tuna (Mauritius)
 The Goal – “Make money now & in the future”…How…

The Goal
Novel by Eliyahu M. Goldratt and Jeff Cox
 Princes UK – Foods Maintenance
Practice Best Practice Activity Type
( Typical) *
Check to see if
Condition 10% 25%
failed
Based
Maintenance Check to see if
8% 33%
failing
Fixed time /
Periodic
78% 5% cycle
Maintenance
maintenance
Re-design
- 2% 4%

Planned run to
Breakdown failure – no
2% 33%
Maintenance business
impact

100% 100%

Sources - The Lean Manufacturing Journal

- Onsite Insights
- AMIS Benchmarking data
 Getting Started
We agreed on some principles…

The Five Fundamentals of Princes Asset Management

1. Increase Employee Involvement in Asset Care.

2. Stop Accelerated Deterioration.
3. Restore Basic Condition.
4. Move From Reactive to Proactive Maintenance.
5. Deliver New Equipment that can deliver Flawless Operation
From Day One with the lowest Life Cycle Cost
We Visualised our Journey to World Class Asset Management.
90%
Performance
Efficiency
Zero
Breakdowns

Supporting
Business
Improvement

Breakdown
Maintenance

Condition Based
Maintenance Incorporating
Autonomous
Maintenance
Periodic
Maintenance

Reactive Proactive

Princes Current Position

Getting Started – Then we drew out a map of the whole
PMS system …

PMS Roadmap 2015

PMS Roadmap First Draft Approx. 2010

 Then we prepared an PMS audit…….

Section Details Questions Section Score Zero’s

Management Information
Theme 1 11 1.0 – 1.11
Do we clearly understand what we should be doing?
Measurement
Theme 2 10 2.0 – 2.10
Do we know how to measure and track progress on our plans?
Man / Woman
Theme 3 11 3.0 - 3.11
Do we have the right skills and structures among our people to deliver on our plans?
Methods
Theme 4 11 4.0 - 4.11
Do we have standard work for our people to follow?
Machine
Theme 5 16 5.0 - 5.16
Do we have sufficient capacity and capability in our equipment?
Materials
Theme 6 3 6.0 - 6.3
Do we have the right quality and availability of materials to achieve our plans?
Enablers
· Do we know how to manage change?
Theme 7 3 7.0 -7.3
· Do we know where our real bottlenecks are?
· Can we think creatively about our business challenges now and in the future?
 Development levels agreed…..

0 Points 1 point 2 points 3 Points 4 Points

Ref Criteria Not Started Beginning Competent Proficient Expert
Level 1 Level 2 Level 3 Level 4 Level 5

Within the site MWBP, a

detailed AM deployment plan
Within the MWBP more
AM/PrM deployment plan Within the MWBP Plan, a has been defined which
detailed plan for the AM Pillar
AM deployment plan is ad- basic stand alone plan for the clearly illustrates the linkages
5 .1 None has been defined with some
Evidence –AM deployment hoc AM deployment has been between AM and all related
linkages to other pillars e.g.
plan defined activities in the 5S,
5S.
Professional Maintenance
pillars

AM Programme
Deployment AM Steps 1-3 only been AM Steps 1-3 fully (100%)
AM Steps 1-3 only been AM Steps 1-3 deployed in
5.2 None undertaken on AA,A and deployed in all areas where
undertaken in pilot area(s) over 50%, of the site
Evidence –AM deployment Constraint machines applicable
plan
Baselines & targets set………

Level 1 Level 2 Level 3 Level4 Level 5

Not Started Beginning Competent Proficient Expert
0 Points 1 Point 2 Points 3 Points 4 Points
5.1 AM / PrM Deployment Plan 3
5.2 AM Programme Deployment 1
5.3 AM Benefits - Impact on Loss Tree 1
5.4 AM Activity Boards 1
5.5 AM Step 1 Initial Clean - Tools, Material & PPE 4
5.6 AM Step 2 Identification of SOC & HTA 1
5.0 Machine

5.7 AM Step 3 Development of Lubrication Standards 1

5.8 AM Step 3 Development of Provisional CIL Standards 1
5.9 AM Support - Leader Training 3
5.10 AM Support - Leader Involvement 1
5.11 PrM Maintenance Strategy 1
5.12 PrM Maintenance Strategy - Communication & Understanding 2
5.13 PrM Support for AM 1
5.14 Optimised Line Philosophy & V Curve 1
5.15 Centre-Lining & the Elimination of Adjustments 3
5.16 SMED 1
Next Steps for AM – Practitioner training….
5 Day Certified
Princes AM
Practitioner
training
Princes Manufacturing System - Asset Management Development Roadmap

Pillar Preparation Phase Stability Phase Flow Phase

AM AM Program Deployed. Aligned

Establish RCA RCA Data Base Causal
Practitioners to PrM Ledger development &
Data Base Factor Analysis
development SAP-PM

PrM PrM Step 1 PrM Step 2 PrM Step 3 PrM Step 4

PrM Step 0
Preparation for Practitioners Supporting Apollo RCA Maintenance Countermeasures
Preparation
AM, PrM - development AM Focus Standards For Machine Weakness
Asset
training &
Management
education. Effective MEOSI Skill
Stores Development
5 day PrM Management Program
Princes 2 Day Apollo
Practitioner Prep. For EEM RCA training
Embed EEM
training EEM Start
training & Process
Deployment
education

Asset
Management
Awareness for 5 day EEM
Leadership Princes
Teams Practitioner
training
 Day 2 Tuesday Day 3 Wednesday Day 4 Thursday Day 5 Friday
Day 1 Monday

C  FACTORY Based FACTORY Based FACTORY Based FACTORY Based FACTORY Based
o Arrival & Registration Learning Review Learning Review Learning Review Learning Review
n Welcome & Introductions Step 1 Initial Cleaning Step 2 Reducing the time to clean Step 3 Standards and Lubrication Examination
t Introduction to Autonomous Maintenance & Team Presentations Team Presentations Step Auditing 100 Day Planning
e Organisation Team Presentations Factory Presentation from teams
n AM Preparation – Step 0 Closing awards
t Team Presentations

O Basic understanding of AM Clean Machine & Identified problems Machine Improvements Step 3 Activity Board Certified Practitioners
u Risk assessments Step 1 Activity Board Step 2 Activity Board Step Audits 100 Day forward Plan
t Initial education Step Auditing Activity Board
p Step 0 Activity Board
u
t

A
M 08:00 Team Time 08:00 Team Time 08:00 Team Time 08:00 Team Time

09:00 Registration & Coffee 08:30 Team Learning Review 08:30 Team Learning review 08:30 Team Learning Review 08:30 Examination (1hr)
Welcome, Introductions Step 1 Introduction Step 2 Introduction Step 3 Introduction
& safety Brief Step 1 Practical Briefing Step 2 Practical Briefing Step 3 Practical Briefing
Introduction to AM Team Preparation Team Preparation Team preparation

10:15 Coffee 10:30 Coffee 10:30 Coffee 10:30 Coffee 09:30 Coffee

AM Preparation - Step 0 10:00 100 Day Planning

10:30
Step 0 Practical Briefing 100 Day Plan practical
10:45 Step 1 Practical 10:45 Step 2 Practical 10:45 Step 3 Practical Final Presentation Prep.
Step 0 Practical
11:15
Team Preparation

12:20 & Lunch 12:30 Lunch 12:30 Lunch 12:30 Lunch 12:30 Lunch

P 13:15 Introduction to Step Auditing 13:30 Final Presentations

M Step Audit Practical Briefing 14:30 Awards
13:15 Step 0 Practical 13:15 Step 1 Practical Continued 13:15 Step 2 Practical Continued
Team Preparation

15:00 Coffee (Informal) 15:00 Coffee (Informal) 15:00 Coffee (Informal) 15:00 Coffee (Informal) 15:00 Close & Depart

15:20 Step 0 Practical Continued 15:20 Step 1 Practical Continued 15:20 Step 2 Practical Continued 15:15 Step Audit Practical continued

16:30 Team Presentations 16:30 Team Presentations 16:30 Team Presentations 17:15 Team Presentations
17:30 Close 17:30 Close 17:30 Close 18:00 Close
Standard work for the 5
day AM Practitioner
Machine Stoppage Machine Stoppage Machine Stoppage workshop
Machine Stoppage
13:30 – 16:00 Observation & Minor Stoppage 11:00 – 15:00 Locked-off & isolated for initial 10:45 – 12:30 Minor Stoppage 10:45 – 12:30 Minor Stoppage
clean 13:00 – 15:00 Locked-off & isolated
Then continually track AM progress…..Measures & “Show
& Tell”.
Asset Management meeting rotates around
group.
Every meeting includes a “Go See”.
Meetings led by senior Manufacturing &
Engineering Directors.
All sites , within scope, represented at the
meeting.

Autonomous Maintenance - Status Summary Month or Week no Jul-13 Aug-13 Sep-13 Oct-13 Nov-13 Dec-13 Jan-14 Feb-14 Mar-14 Apr-14 May-14 Jun-14 Jul-14

No/Project Machine Description Criticallity Planned Start Date Saving Target AM Steps Planned Intro Zero Trn Zero prac

AM Steps Actual Intro Zero Trn Zero prac Step 0 85%

Ledger Development Planned

Rinser AA
B Shift
line 1 RFC Filler AA Oct-13 5% reduction in downtime
RFC Ledger Development Actual
Capper A
Centrelining Planned

Centrelining Actual

Autonomous Maintenance - Status Summary Month or Week no Jul-13 Aug-13 Sep-13 Oct-13 Nov-13 Dec-13 Jan-14 Feb-14 Mar-14 Apr-14 May-14 Jun-14 Jul-14

No/Project Machine Description Criticallity Planned Start Date Saving Target AM Steps Planned Intro Zero

AM Steps Actual Intro Zero started Zero 85%

Ledger Development Planned

C Shift Line 2 Palletiser B Aug-13 5% reduction in downtime
Ledger Development Actual

Centrelining Planned

Centrelining Actual
Princes AM journey – our learnings so far for 4.0
Soft Learnings -
Find a change model, use it
& stick to it.
Start from “why”.
It’s Important everyone
learns together.
All “tools” require good
leadership & behaviour.
Principles are powerful.
Better a small job done well
than a big one done badly.
Hard Learnings -
The little things really do eat
your lunch.
Understand your losses –
its not as easy as you think.
Criticality is critical.
Centrelining works.
The ledgers are especially
important but are very hard
work.
Next steps…
Improving Delivery of -
Flawless Operation
From Day One. Next - Link to
EEM Voice of the Customer

PrM

Improving Delivery of -
Specialist Support.
Next - Full CMMS integration
AM
Improving Delivery of -
Equipment Competent
Workforce.
Next - Leadership &
Behaviour development.