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MBUs 5S
Occupational Health and Safety
Blayney Bonus Points
MBUsMBUs 5S5S
Occupational Health and SafetyOccupational Health and Safety
Blayney Bonus PointsBlayney Bonus Points
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Mini Business UnitsMini Business UnitsMini Business Units
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Theme
ProfessionalismProfessionalism
Its aboutBlayney willinglyengaging our
ResourcefulnessResourcefulness= Having a fair dinkum go . Persevering . Finding ways.
EssentialsSafetyQuality
CommunicationTeamwork
= Prosperity for You, Us, Company, Community, Country.
Skills
Hugedevel
opment
&increasedusage.
-2004
Management
Focus back in
the Factory
ESSNewequipmentandnewproducts.
=FoundationforReliability,IncreasedSales&Profitability.
=SelfDisc
overy,Curio
sity,
Learning,T
raining.
Values. Esteem, Empathy, Involvement, Share, Support.= Bringing the best out in ourselves and others.
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5S5SPeople in organisations where 5S has been implementedeffectively, can answer Yes to the following questions
Do you know exactly what things yourworkplace needs and does not need?
Do you know exactly what things yourworkplace needs and does not need?
Can you tell by simply lookingaround where each item is stored?
Can you tell by simply lookingaround where each item is stored?
Are quantities clear at a glance?Are quantities clear at a glance?
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5-S Practices5-S PracticesS1 Sort and Discard eliminatesnon-essential items from theworkplace. A pleasant andefficient workplace is created.
S2 Shine removes dirt, grime anddust from the workplace by
thoroughly cleaning equipment,floors and walls.
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5-SPractices
5-S
PracticesS3 Signpost and Orderensures
that there is a place for everythingand that everything is in its place.Everything must be sign posted sothat it is visually clear where things
belong.
S5 Sustain refers to the disciplinerequired to ensure that S1, S2, S3 and S4are properly maintained and improved.
S4 Simplify Work byapplying ergonomicprinciples to the workplaceto eliminate wastefulactivities and make worksafer and easier.
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Visual Workplace - 5s OpportunitiesVisual Workplace - 5s Opportunities
Workshop requiring improvements Workshop with improvements made
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Visual Workplace - 5s OpportunitiesVisual Workplace - 5s Opportunities
Tool box & workbench requiringimprovements
Workshop with improvements made
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Visual Workplace - 5s OpportunitiesVisual Workplace - 5s Opportunities
Store room requiring improvements Store room with improvements made
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SafetySafetySafety
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PEOPLE - SHEPEOPLEPEOPLE -- SHESHE
We have been the worst performingNestl site within Oceania.
The safety culture at Blayney was
negative, people saw safety as an addon to their normal roles and tasks.
With this way of thinking, changing the
culture and behaviours was going to bea challenge.
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The Worst PerformingSite..July 2002
The Worst PerformingThe Worst PerformingSite..July 2002Site..July 2002
Blayney
Lost Time InjuryFrequency Rate
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Today .a 85% reductionToday .a 85% reductionToday .a 85% reduction
September 04 Leaderboard Manufacturing
DC & Sales Offices LTIFR 12 Month Rolling Average
23
2017
1613
131212
1111
111010
99999
87
66
5
1
3
1
000
0 5 10 15 20 25
Broadford
Altona
Pakenham
Echuca
CDS Brunswick
Dennington
Murarrie
Auckland Sales & HO
Smithtown
Blayney
Noumea
Nestle 2004 Target
Campbellfi eld
Perth
Blacktown
Port Melbourne
Oceania
Tongala
Arndell Park
Cambria Park
Mulgrave
Ba
Head Office
Lae
Dandengong
NZ Purina Sales
Adelaide
Gympie
Marton
Sept 2004 BlayneyLost Time InjuryFrequency Rate
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PEOPLE SHEPEOPLEPEOPLE SHESHE
11.4Rolling 12mth Sept. 04YTD 2004 = 4
29.720032003 = 15
44.520022002 = 22
64.420012001 = 36
39.720002000 = 35
LTIFRLost Time Injuries
Premium Costs2003 = $1,600,000 budget
$1,100,000 actual2004 = $975,000 budgetCurrent 04 forecast = $650,000
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12
68
15
20
23
2830
32 3334
13
67 7 7 7
1114
0
5
10
15
20
25
30
35
40
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Months
Num
ber
Blayney W/ Comp Claims 03 Blayney Claims 04
Blayney Workers Comp ClaimsBlayney Workers Comp Claims
CumulativeCumulative
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How....How....How....
Commitment by Everyone,
Everywhere,
Everyday
1. A Shared Vision for Safety
Global target LTIFR = 10
People are our most important asset
2. Focus on Behaviour
BBS Safety Chats, Observations, Videos, Safety Alerts, Monthly
Factory Inspections Move@Work
Training
Risk Management
Early intervention of Injury Management
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3. Enabling structures to get Goal Alignment
MBUs
4. Capital Investment / Robotics reduction of manual handling
5. Cultural Alignment getting everyone to pull in the same direction
6. Nestl Wellbeing Program Gut Busters, Quit Smoking,
Cholesterol Checks, Flu Vacs, Diabetes checks, BloodPressure Checks, Skin Cancer Screening
How....How....How....
Commitment by Everyone,
Everywhere,
Everyday
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Blayney Bonus PointsBlayney Bonus PointsBlayney Bonus Points
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Blayney Bonus PointsBlayney Bonus PointsBlayney Bonus Points
MSA Target > 95% Site Safety Target (LTI Free days)
Environmental / Waste Target Wet Product Scrap 2.2% site target
Dry Product Loss
Rework < 4.0% and Dry Product Scrap < 1.0%
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People will be able to win Blayney Bonus PointsAnd these will be redeemable at the :
CanteenCanteen
Staff SalesStaff Sales
To buy Company ProductsTo buy Company Products,Jackets, Hats ,Sports Bags Glasses etc
All Employees will be able to try win things like:
CRUISESCRUISES,, MYSTERY FLIGHTS,WEMYSTERY FLIGHTS,WEEKENDSEKENDS
AWAYAWAY AND MUCH MORE:AND MUCH MORE:How :
Delivery, Safety, Quality, Good Housekeeping, Line Performance,Implementation of New Ideas
Who: This is a site wide initiative for all NPP personnel.
Blayney Bonus PointsBlayney Bonus PointsBlayney Bonus Points
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1. MSA > 90% - The Challenge:
MSA >90%= 10 Blayney Bonus Points(BBPs) per week across the site.
1st MSA >90% for 1 week will also include a Site BBQ cooked by NPP MgtStaff
MSA >90% for 3 consecutive weeks = BBPs & Site wide Thank You Gift
MSA >90% for 6 consecutive weeks = BBPs + Gift & everyone in the drawfor the mystery cruise, weekend away or gift vouchers.
Awards acknowledged weekly at MBU3 meeting.
Note: 1 Blayney Bonus Point(BBP) =s approximately $1
Blayney Bonus PointsBlayney Bonus PointsBlayney Bonus Points
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2. Site Safety
50 days LTI free = 25 BBPs
* Repeat 25 BBPs at 100 days , 150days and 200days.
3. Waste Targets
Provide focus on achieving efficiency objectives. Primary driver is toconsistently achieve high performance in the areas of waste minimisationand cost control.
5 BBPs for achieving dry targets weekly (Rework < 4.0% and
Dry Product Scrap < 1.0%) 5 BBPs for achieving wet targets weekly (2.2% site target)
Benefit for the factory in achieving these targets = $20,000 saving per week
Blayney Bonus PointsBlayney Bonus PointsBlayney Bonus Points