Revision: 06
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Contents
The purpose of this file is to document the approved and
latest versions of:
Driving
Pillar
Routes
Improvement
Routes
Kaizens
RCFAs
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FI Pillar
New FI Pillar Step 5 for Energy and Water including roadmap to 2020 E&W vision
AM
No change
No change
PM Pillar
Removed Breakdown Reduction, Route - recommend to use RCFA or Kaizen. Removed Minor
Stoppage Reduction Route recommend to use MSAS. Removed Speed Loss Routes
recommend to use Kaizen.
PQ Pillar
T&E Pillar
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Pillar Route
Improvement Routes
Reduction of accidents, incidents and near misses team route
Operational Risk Reduction (ORR) team route
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Systematically analyse
accidents & incidents
1
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New
ENVIRONMENT
SAFETY
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New
1. Map Solid Waste, Waste Water, Water & CO2 emission current
status
2. Make gap analysis to set priorities
3. Monitor data & solve anomalies
4.Identify improvement opportunities (Renewable Energies, Waste &
Waste
Water reduction, recycling, etc.)
5. Define new standards & visual management
6. Benchmarking & good practice sharing
7. Integrate/optimise SHE management system
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Improve management
system to hold the gains
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Standardisation
Detailed Risk
Assessment
Identification of hazards
& hazard controls
Restoring Basic
Conditions
Data Collection
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Standardisation
Detailed Risk
Assessment
Identification of hazards
& hazard controls
Restoring Basic
Conditions
Data Collection
1.Make communication/machine
board
2.Define safety audit combined
with AM/5S audit
3.Develop indicators &
monitoring system
Driving System
Organisation & Change Management Contents
HPO Model & Route
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HPO
HPO
HPO
Concept
Concept
Ldr Team
Leadership Team
Driving
Driving System
System
Process
Process
Results
Results
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New
Business
Results
Structure
Rewards
Decision
Making
Tasks
People
Information
Culture
How the organisation really operates
1.Attitude towards strategy & goals
2.Actual distribution of power & rewards
3.Actual work people do/dont do
4.Other norms that explain how things
get done (or not)
Organisation Design
Elements
* Source: Hanna-High Performance Organizations
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Future
Business
Situation
New
Current
Business
Results
Business
(Operating)
Strategy
Design
Elements (DE)
(Step 4) Identify Issues
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Culture
(Step 3) Examine
New
Current
Business
Results
Future
Business
Situation
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Business
(Operating)
Strategy
Design
Elements (DE)
(Step 7) Changes to
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Culture
(Step 8) Predict
impact of DE
New
Steps 6 8
ReDesign
Process
Steps 2 5
Assessmen
t Process
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New
1.Know the current business (operating) strategy formal & unwritten to identify if they are a reason(s) for the critical issues identified in the d
2. Assess the fit between the actual operating strategy & what the busines
situation
requires in the future
(Vision, Mission, Strategy, Operating Principles, underlying values and
assumptions,
Objectives & Goals (KPIs))
1. Assess one by one the critical cultural aspects & behaviours in respect of
the 6 design elements (this identifies the design strengths &
opportunities )
2. At the level of design element (if possible) cluster the issues by common
problems
3. Prioritise the issues to be solved
1. With the team examine how each result (good or bad) is achieved & ask
which organisational cultural aspects / behaviour(s) can be responsible
for it?
2. Confim at the GEMBA what the people say & what you see (focus on
observable behaviour)
3. Prepare a statement of positive behaviours we want to keep
4. Priortise the critical cultural aspects / behaviour(s) that need to
investigated further
1. Describe the future situation in terms of hard numbers, company
requirements social, political, legal expectations, competitive pressure &
expectations of employees
2. Identify the current results
3. Perform a gap analysis - determine which results need to improve &
which should be maintained (good & on track)
4. Prioritise the gaps to define the order in which they will be addressed
1. Define the theme & boundary, assemble the right group of people
2. Identify & map the entities that interact with the boundary
3. Describe the existing tranactions (formal processes) & relationships
between the boundary & each entity
4. Map the influence of the different entities on the boundary results
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New
1. Prepare a comprehensive summary of the changes to be implemented
1. Revised operating strategy
2. Detailed list of changes to the design elements
3. Communication plan
4. Major changes expected in organisational culture
1. Identify the positive & negative impacts the new design elements will
have on the organisational culture
2. Re-visit & adjust the design of the 'Diamond' in order to avoid the
predicted negative impacts
1. List the tasks that need to be performed in order to fulfill the new
operating strategy
2. Develop the other 5 design elements to reinforce the high performance
of these tasks. (Ensure all new design elements are cross-checked to fit
with new operating strategy)
1. Assemble again the team members to discuss, confront each other &
eventually reach a consensus on each point (as below) of the new
operating strategy
1. Purpose, vision & mission statement
2. Competitive strategy
3. Operating Principles
4. Objectives & goals
5. Underlying values & assumption
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Pillar Route
Improvement Routes
Changeover Time Reduction
Team Efficiency
Energy Reduction
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New
Step
5
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Define standards to
maintain results
Understand current
situation
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Pillar Route
Team Route
Detailed Actions for AM Team Step 4
Detailed Actions for AM Team Step 5
Detailed Actions for AM Team Step 6
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Und
e
revis r
i on
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Finalise the
inspection program
General inspection
Specific training
on technologies
and component
General training
Preparation
of the training
Machine parts
classification
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Material losses
reduction
2
1
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Energy losses
reduction
Finalise Control
Points
Quality losses
reduction
Analysis of the
machine process
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Finalise Control
points
Energy losses
reduction
Material losses
reduction
Quality losses
reduction
Analysis of the
machine process
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Improvement of
organisation items
Reduction of walking
pattern
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Improvement of
organisation items
Reduction of walking
pattern
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1. Review team
2. Create layout, workflow and
specification
3. Understand improvement
requirements
4. Detailed cost planning
5. Detailed activity planning /
supplier
6. Design review basic
engineering
7. Procurement
8. P&EEM Workshops
9. Change control procedure
10.Organisation & Maintenance
planning
11.Manufacturing
1. Review team
2. Installation Risk assess. &
mitigation plan
3. Installation standards &
Procedures
4. Defect detection and LOI
5. Commissioning
6. Transfer and Acceptance
Protocol
7. Operation Optimising Phase
8. Site Acceptance Test
9. Project evaluation
10.Closure of project
1. Review team
2. Set up LOR
3. Understand existing situation
of plant
4. Equipment planning & MP
data availability
5. Risk Management
6. Basic cost planning
7. Activity planning
8. Design review
9. Investment application
Improvement Routes
Maintenance Standards Team Route
RCFA/Kaizen
Breakdown analysis
Minor stop analysis
Kaizen Sheet
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1.
2.
3.
4.
1.
2.
3.
4.
Note: at end of each step summarise
impact on problem and key
learnings
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Rem
oved
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Rem
oved
Rem
oved
1. Plan & implement
countermeasures
2. Communicate improvements
using OPL
3. Repeat step 3 to find
additional causes
4. Follow up results
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Component by component:
1.Define criticality
2.Define maintenance strategy
3.Define preventive and corrective
task
4.Define resource for task
5.Check for opportunities to cluster
tasks
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Pillar Route
PQ Pillar Roadmap
Improvement Routes
Extract Loss Reduction Team Route
Packaging Material Loss Reduction Team Route
Defect Reduction Team Route
Microbiology Defect Reduction Team Route
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Product Stability
Capability
Reliable
Machines & Process
Reliable &
Predictable Process
Capable Process
Guaranteed Quality
UCL
USL
LCL
LSL
Bronze
Silver
Out of
Control
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New
Gold
New
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Quality Excellence
Quality Assurance
Quality Control
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4
3
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Quality Control
New
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Quality Assurance
New
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Quality Excellence
New
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lity
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)
nce
(Pers
onne
l)
Improve
Qua
nce
nel)
Mai
nten
(Pers
on
Mai
nten
a
l)
Quality
Excellence
lity
(Tec
hn o
logis
ts
uali
ty
(Tec
h no
logis
ts)
olog
ists)
onne
Mai
nten
ance
(Pers
Quality
Assurance
Maintain
(Tec
hn
Qua
Quality Control
7.-People Development
EXTERNAL SC SCOPE
New
Gold
Silver
Bronze
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ADVANCED
PKE
New
QUALITY
PKE
Quality Control
Quality Assurance
Quality Excellence
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We a Note:
re co plan (assign
1. Define
to co action
ns
m
eringdates)
binesetiddue
actions
Pack and
D
e
a
f
e
ging planned
ct &corrective
2. Implement
Ma
actionsRoute terials
s
We a Note:
r
to co e consid
mbin
ering
Pack
e
agin Defect
gM
&
Rou aterials
tes
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Improve the
management system to
hold the gains
Implement improvement
actions
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6
5
4
3
2
1
Improve the
management system to
hold the gains
Pillar Route
Improvement Routes
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Und
e
revis r
i on
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5
4
3
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Evaluate results at 4
levels
Formulate
requirements for
implementation at
work place
Design learning
situation and
develop learning
materials
Detailed analysis
learning /
development needs
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Evaluate results at 4
levels
Formulate
requirements for
implementation at
work place
Design learning
situation and
develop learning
materials
Detailed analysis
learning /
development needs
Note: at end of each step summarise
impact on problem and key
learning's
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5.1
5.2
5.3
5.4
3.1 Define all relevant conditions that may influence the application of skills at
work
related to learners
3.2 Define all relevant conditions that may influence the application of skills at
work
related to immediate supervisors
3.3 Define all relevant conditions that may influence the application of skills at
work
related to Organisation and Management
2.1 Design Learning Situation
Take into account the 70 20 10 Learning Philosophy
2.2 Develop Learning Materials
2.3 Select participants
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Und
cons er
truct
i on
Early Product Management Pillar Contents
Pillar Route
Improvement Routes
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Revision Management
Revisio
n
No.
Date:
Documen
t
type:
Issued
by:
Oct 2011
STD
C. Kerr
Jan 2012
March 2012
May 2012
Jan 2013
Revision Comments
Creation document.
New Safety Pillar Route; 5 steps introducing overall management system
approach.
New P&EEM Pillar Route and Project Implementation Team Route.
New visual identity, only use master for slide ID, update various routes from
EFESO to new visual identity+added banner not to be used yet.
New PM Pillar Route, BDA sheet, Minor Stop Sheet. New Changeover Route.
Extract loss and Micro Defect Reduction Routes updated.
SHE Pillar ENV Steps added for already Bronze Brerweries
Org & C Mgt - HPO Model & Route
May 2013
New FI Pillar Step 5; reviewed sub steps including roadmap to 2020 E&W vision.
PM Pillar Breakdown, Minor Stoppage & Speed Loss Reduction Routes removed;
instructiojn is to use RCFA, MSAS or Kaizen only.
Quality Roadmap linked to Bronze, Silver, Gold...
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