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Lean Manufacturing & its relevance to onshore bottling
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  1. Lean Manufacturing & its relevance to onshore bottling from a contract bottling perspective

  2. Three channels that use offshore packaging • Offshore corporations that own New Zealand wineries (more than 2/3 of NZ’s wine industry)

  3. Three channels that use offshore packaging • Offshore corporations that own New Zealand wineries • Offshore retailers and distributors

  4. Three channels that use offshore packaging • Offshore corporations that own New Zealand wineries • Offshore retailers and distributors • Speculative ‘Brand Engineers’ exploiting a supply imbalance and a high currency

  5. Bottled vs Bulk exports (MAT)

  6. Bottled vs Bulk exports (MAT) 20% up this month on last year!

  7. Offshore Value capture

  8. Offshore vs Onshore manufacturing

  9. Offshore vs Onshore manufacturing

  10. Offshore vs Onshore manufacturing

  11. Offshore vs Onshore manufacturing

  12. Offshore vs Onshore manufacturing

  13. Offshore vs Onshore manufacturing

  14. Offshore Manufacture

  15. Offshore vs Onshore manufacturing

  16. Offshore vs Onshore manufacturing

  17. $20.59 $18.82

  18. $19.72 $20.59 $18.82

  19. $19.72 $16.68 $20.59 $18.82

  20. Packaging cost: NZ vs offshore:

  21. Lean Works for Wine Works

  22. Our Enemy: Offshore Bottling • WineWorks implemented lean into our sites 5 years ago, with a vision of combatting our new enemy: “offshore” bottling. We needed to become more efficient and cost effective. • The key to everything is having the ability to measure your performance in all areas of your business. If you don’t know where your are, how can you find your way forward?

  23. First: Call the engineers !! • The following presentation is from an engineering aspect, and is in no way the only thing we needed to do. • There is never only one thing, and changes take place in all areas of the business. HR, Planning, Logistics, Production, Transport, Procurement etc. • Three basic legs: 5S, Visual Displays and Kaizen

  24. Operator Setup done by Engineers

  25. Planned/Preventative Maintenance

  26. Reduction in Mechanical Failure

  27. Engineers Call Outs

  28. Kaizens & 5S • Ideas are one of the key aspects of lean, and most of what we achieved in the following section came from 5S, Kaizens and team work. • 3 basics: Kaizen 5S Visual Displays

  29. Total Cost/Case

  30. Cases Produced

  31. Cost/Case vs Volume

  32. Filler Spend $

  33. Labeller Spend $

  34. Electrical Spend $

  35. Electrical Spend

  36. Electrical Spend

  37. Electrical Spend

  38. Cost/Case vs Volume 17 % Cost reduction

  39. The end

  40. Offshore advantage: Overcome by Lean Manufacturing

  41. Offshore advantage: Overcome by Lean Manufacturing + 17% !!