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Fine Organics Limited

Fine Organics Limited. Chris Steel Continuous Improvement Manager 12 th May 2011. Company / Site History. 1977 Company founded on Peterlee site 1984 Laporte acquired controlling interest 1984 New Seal Sands Site opened 1985 MPB-1 commissioned 1986 MPB-2 commissioned

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Fine Organics Limited

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  1. Fine Organics Limited Chris Steel Continuous Improvement Manager 12th May 2011 Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

  2. Company / Site History 1977 Company founded on Peterlee site 1984 Laporte acquired controlling interest 1984 New Seal Sands Site opened 1985 MPB-1 commissioned 1986 MPB-2 commissioned 1989 MPB-4 (Pilot Plant) commissioned 1996 MPB-3 commissioned 1998 R&D & QC laboratories opened • Laporteacquired by Degussa 2007 Changed name to Evonik • (Nov) Management Buy Out Fine Organics Limited (Fine Industries) 2011 What’s next ??????? Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

  3. Fine Organics Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

  4. Fine Organics Manufacturer of a wide range of chemical intermediates and active ingredients for the following markets: Pharmaceutical Agrochemical Specialty Chemical Development and hazard testing labs On-site incineration capability Permanent Employees 184 Full time contractors 30 Manufacturing Plants 4 Reactor Capacity 325 m³ Total Site Area 55 acre Developed area 25 acre Accreditations : ISO 9001 ISO 14001 Responsible careFDA inspected site Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

  5. Customer care Change and innovation We will pursue opportunities for our business, our customers and our people without compromising SHEQ standards. Continuous Improvement Sustainable Quality, Cost and Delivery, targeting best in class & demonstrating operational excellence in all that we do. SHEQ Fully integrated business approach to safety, health, environment and quality. Our people and teamwork Success can only be achieved through our people operating as a cohesive team,in an empowered and rewarding work environment. Core Values Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

  6. “Where are you on the never ending road towards excellence?” 12th May 2011. Fine Organics Limited Chris Steel Continuous Improvement Manager

  7. How did we get from this……. Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

  8. to this……… Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

  9. From this…….. Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

  10. To this……. Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

  11. From this…….. Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

  12. To this……. Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

  13. From this…….. Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

  14. To this……. Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

  15. August –Jan 2011 6 months @ 100% Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

  16. Jan 2011 8.5 Stock Turns Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

  17. Achievements • Conducted site wide training and 8 major master classes resulting in savings in excess of £580,000 cash, 18,000 vessel hours & 7980 Man hrs • Developed and introduced an OEE monitoring hardware and software system operable in a hazardous environment. Efficiency savings of £500,000. • Developed a structured approach to process improvement "cpot” • VSM (Value stream map) on all key process’s • OEE data analysis now site wide • CPOT • Prioritised action plans • These changes have resulted in real improvements on key process • Increase throughput on one Key process from 3.5 to 5.5 batches per/week (57% increase) • Increased KG's produced per vessel/hr on a second key process from 8.56kgs to 13.82Kgs (61.4%) • Reduced Clean down and Change over times by 40% • Winners of the 2010 CIA award – shortlisted for 3 othersFor Development of Business Improvement Software Systems • Implemented the “Nissan Maintenance System” concentrating on Break Down Rate. Reduced BDR from 36% to 13% = £400,000 benefit. • Continue to improve through a structure of “Kaizen improvement teams” • We continue to make Continuous Improvement “a way of life” Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

  18. Peter F Drucker “There is nothing so useless as doing efficiently that which should not be done at all” “90% of all improvements are common sense, it’s having a structured approach to implementation that counts ” Chris Steel Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

  19. We started on our Journey in Jan 2007 • Decided where you are and where you want to be? Bench Mark Training Culture Funding / Partners Policy deployment

  20. Which vehicle do you use?

  21. Who’s on the journey? • Senior / Middle management • Operational Staff • External Help! • A driver

  22. Dedicated facilities Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

  23. What tools do we use? OEE Data CPOT SMED Problem Solving VSM Line Balance What Type of Tool Box ? Lean Toolbox Root Cause Analysis BDR reduction Standard Operations Visual management Plug Game 7 Wastes 5 S Policy Deployment KPI’s

  24. Linked to the (BMS) Business Management System Batch card CPOT MPB4 At home BMS In the office OEE Data capture On the move KPI’s BMS Saturday, September 6, 2014 24 Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

  25. In summary • Lean can be implemented in any organisation • There is no silver bullet • Needs to be part of an overall strategy and Shared Vision • Plans need to be in place • Rolled out through policy deployment • Need sufficient resources • Need people to be resourceful • Educate your people in tools and techniques • It is not a quick fix – it’s a long journey - Sustainable • Stick with it • Keep it simple • Make it a……. “a way of life” Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

  26. So where next for us? Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

  27. New Company Structure As current Rapid response to enquiries Target market 1g – 50g Access to non traditional Markets Commercialise Business Management System to a variety of customers Data entered once and used by all Reduce costs and enhance performance. 1 of only 3 incinerators in the UK Strategically positioned Flexibility to burn a variety of wastes Security / Infrastructure in place Building and plant maintenance Contract & Project Management Administration

  28. Fine Industries Ltd: An innovative group to create value for its customers. Continuous Improvement “a way of life”

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