Winner of the CCi Performance Excellence Award 2024
The challenge
When initial assessments revealed a concerning OEE performance on the EVM line, Alaska was facing mounting operational difficulties. Key challenges identified across the facility included persistent production interruptions, inadequate equipment maintenance, and unreliable processes.
The situation was further complicated by challenging shop floor conditions, frequent changeovers, and excessive short stoppages that impacted both productivity and workforce morale.
Industry
Food and Beverage
Alaska Milk Corporation, established in 1972, has a rich history of nourishing Filipino families for over 50 years. As one of the Philippines’ leading food manufacturers, the company is committed to delivering high-quality dairy products while maintaining operational excellence across its manufacturing facilities. FrieslandCampina, a prominent Dutch multinational dairy cooperative, acquired Alaska in 2012.
The solution
A loss and waste analysis was conducted to identify opportunities for high impact improvements. This was followed by a rapid deployment phase to address the issues identified.
- Planning and Scheduling Optimization
Implement strategic scheduling to reduce changeover frequency from three to two times per week. Optimize production run length through improved sequence planning. Establish advance material preparation and alignment protocols for maximized efficiency. - Short Stops Reduction
Deploy centerline point identification system across production lines. Execute equipment restoration to basic conditions to ensure optimal performance. Develop and cascade new operational standards to the shop floor. Target and achieve reduction of short stoppages of 5%. - Asset Care Enhancement
Transform maintenance approach from reactive to proactive through systematic implementation. Implement comprehensive spare parts management system to ensure availability. Establish preventive maintenance protocols for consistent equipment care. Create equipment reliability improvement program for sustained performance. - Routine Stops Management System
Optimize CIP process through systematic analysis of current procedures. Eliminate identified cleaning-related delays through process improvement. Standardize CIP procedures across operations for consistency. Implement efficiency monitoring protocols for sustained results. - Daily Management System Integration
Deploy structured performance management system for real-time oversight. Install short interval control boards for immediate performance tracking. Enhance shift handover processes with standardized procedures. Implement digital OEE tracking and reporting system for accurate monitoring.
Results
The rapid deployment approach delivered significant improvements in Alaska’s operational performance, but more importantly transformed the lives of those working on the shop floor. The 22% improvement in OEE represents a new benchmark for operational excellence in Alaska’s manufacturing history.
A 22% increase in OEE in six months
Reduced the need for employees to work overtime
Reduced change over times, and downtime by 5%
Zero safety incidents throughout the transformation period
Dramatically improved the lives of employees working on the shop floor
From the shop floor
“I challenged the team go for 90% OEE improvement. The team did a fantastic job by reaching 90% OEE and beyond! We literally improved the shop floor lives of our people. Being more in control and delivering more predictable output.”
From the shop floor
“Because of the rapid deployment our work became easier and we were able to exceed 90% OEE, OWOW!”
From the shop floor
“Before we encountered many issues every day. But now I can’t believe it, we were able to demonstrate 0% technical stops in 1 day!”
From the shop floor
“With the machines running more reliably, we can produce more product in fewer days, meaning more time with our families, OWOW!”
Discover more from FrieslandCampina
Watch this exclusive webinar and Q&A featuring FrieslandCampina Alaska Milk Corporation’s remarkable journey to Operational Excellence. Learn how their innovative OWOW (Our Way of Working) program is empowering employees, streamlining operations, boosting productivity and delivering sustainable step change results.
• A leap from 68%-90% in OEE
• Significant reduction in downtime and changeover times
• Enhanced work-life balance and morale, more time with family and better shop floor lives – OWOW!
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