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Covington

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Covington

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  1. Larry Gibson – Manufacturing Director Covington Sep 2013

  2. Factory Timeline 96 10 09 07 11 03 00 99 98 1996 - 2000 2000 - 2009 2010 - 2011 • Land O’ lakes (copacker of Slim-Fast ) completes construction and inititates start-up. Building size is approx. 400,000 sq. ft. • Slim-Fast Foods Company assumes ownership of Covington • R&D Pilot Plant Start-up • 280,000 sq. ft. expansion (Distribution Center) • Two additional packaging lines installed (doubling capacity). • Processing & canning expanded by 50% • Project Odyssey (Ice Cream). Engineering starts. • Slim Fast RTD production ceases (June 30th) • Ice Cream Manufacturing begins in Space Saver (PIC) on Aug 29th • 1st Stickless extruded Line (Klondike) starts on Oct 26th with Reese’s • Moulded Line starts on Dec 15th with Mighty Minis production • Slim Fast Company acquired by Unilever • High strength waste treatment facility completed • 1st Super-shots line in North America installed and operational • Project Yorktown (Slim-Fast Restructuring) • Project Lexington (Super Shots Exit) 00

  3. The Journey to IcE Cream We are here Adult Teen Child Toddler Infant

  4. Factory Passport PIC - Packaged Ice Cream (Breyers) Production Lines: 14 (pack capacity 206,000) - SS-1: PIC - speed 70cpm - SS-2: PIC - speed 70cpm - SS-3: PIC - speed 70cpm - SS-4: PIC – speed 70cpm - KL-1: Klondike (stickless extruded) – speed 600bpm - KL-2: Klondike (stickless extruded) – speed 600bpm - KL-3: Klondike (stickless extruded) – speed 600bpm - Gram 1: Molded – speed 140 pcs/min - Gram 2: Molded – speed 455 pcs/min - Gram 3: Molded – speed 455 pcs/min - Gram 4: Molded – speed 280 pcs/min - Gram 5: Molded – speed 624pcs/min - Gram 6: Molded – speed 520 pcs/min - Gram 7: Molded – speed 624 pcs/min Stickless Extruded (Klondike) Molded (Popsicle / Good Humor) Building Area: 808,000 sq ft (75,000 sq mt) Land Area: 3,556,000 sq ft (330,000 sq mt) Mix Room: 2 - PIC Mix Room capacity: 6,000gph* (2 HTST*) - Novelty Mix Room capacity: 6,000gph* (2 HTST) Refrigeration: - Current Refrigeration Load: 5,875 ton - Current Ammonia Load: 125,000 lbs STAFFING (Jan/13) 13 Managers 22 Supervisors (WL1) 462 Hourly Employees 178 Temporary Workforce Cold Storage: - Fully Automated – 4,000 pallet positions 2013 Volumes: 95,016 Liton PIC: 54,991 Liton (51 SKU’s) Klondike: 21,655 Liton (4 SKU’s) Molded: 18,370 Liton (12 SKU’s) 2013 Budget: €63.7M at $1,2831: €1.00

  5. Overview • What does a modern foods factory look like? • Automation • Robotics • HMI • What does this mean for operators? • Math/Analytical Skill/Reading comprehension • What Unilever is doing to continuously improve our workforce! • OJT • BLITZ • IRT for All (Unilever University) • Advanced Training

  6. Team Work

  7. Gram Equipment Gram Robotic packaging Automated Case packing Operators Performing a Changeover Consumer Safety, Teammate Safety & Quality

  8. Breyers Modern packaging equipment Space Saver Graphical Equipment representation Automated Downtime analysis Computer Touch Screen Online statistical controls Consumer Safety, Teammate Safety & Quality

  9. Delicious products! Klondike Modern Quality assurance equipment High volume production Klondike Robots Ice Cream Production Consumer Safety, Teammate Safety & Quality

  10. High Tech HTST Mix In department Mixing Calculations Consumer Safety, Teammate Safety & Quality Batching

  11. BasicLearningI ntensiveTraining ZoneTraining Guides Unilever Covington, TN

  12. Training Manualused to guide Operator through all technical aspects of their daily functions. Competency Check Guideused to Validate Operator is fully competent to run the technical aspects of the equipment.

  13. Skills Training Matrix Klondike Warehouse Space Saver Mix

  14. But all this is notenough!

  15. Covington People Development Mission: Enable factory workers to learn and grow their contributions and rewards by building skills that allow them to meet our consumer and company needs • Deliverables: • Skilled/ Flexible workforce • Highly Engaged workforce • Environment where “Variable Pay” is the • Motivation • Competitive Advantage: • Technical Business partners are running the business day to day. • Employees are the investment and deliver stakeholder returns. • The Vision of the Site and Company is internalized and demonstrated

  16. MAINTENANCE PROGRESSION IRT CORE AAS Degree Advanced Industrial Integrated Technology Maintenance Technician III Skill Assessment Test • Prospective Candidates • Soft Skills • Teamwork • Math • Reading • Locating Information • Operator • Blueprint Reading • Measurement • Hand Tools • Mechanical Components I • Bearings & Lubrication • Mechanical Components II • Machine Adjustment Controls C o n T r o l s M e c h A n i a L Mechanical Maintenance Technician II Skill Assessment Test Certificate Programs Electrical M e c h A n i a L C o n T r o l s Electrical Apprenticeship Program O R • Maintenance • Shop Math • Operator Core • Fundamentals • Pneumatics & Hydraulics • Electrical Components • Pump Basics • Valve Operation • Failure Analysis • Gearbox & Bearing • Advanced Pneumatic • Advanced Hydraulic • Advanced Electrical • Pump Maintenance • Intro to Welding • Machine Shop Practices • Machine Adjustments • Ladder Logic • PLC Advanced Electrical • OJT Train-the-Trainer • Basic Machines • Validated Pre and Post tests • CRC • Mechanical Aptitude Certificate Programs Maintenance Technician I Skill Assessment Test • MECHANICAL • Workplace Safety • Preventive Maintenance • Quality Control & SPC • Hydraulic/Pneumatic • Fluid Power Distribution • Piping and Pneumatic • Mechanical Installation • Basic Pneumatic Controls • Basic Hydraulic Controls • Intermediate Pneumatic • Intermediate Hydraulic • Power Transmission Systems • Advanced Mechanical • ELECTRICAL • Workplace Safety • Preventive Maintenance • Quality Control & SPC • Basic Electricity • Power Development • Electrical Power Distribution • Electrical Installation • Basic Electrical Controls • Intermediate Electrical Controls • CONTROLS • Workplace Safety • Preventive Maintenance • Quality Control & SPC • Principles of Instrumentation • Integrated Process Control • Integrated Process Management • Programmable Logic Controls

  17. So we leverage our Partnership with Southwest! Unilever University sponsored by Southwest Tennessee Community College