Description
Coached Improved the detail cleaning plan of the production facility by incorporating scheduled sanitation periods quarterly to address standards of the Food Safety Modernization Act (FSMA). Improved the microbiological results for Environmental Monitoring Program by 85 percent reducing chemical cost by 45 percent. Negotiated a new Cleaning Service Contract that has saved the Carrollton Facility 35 percent versus the previous Cleaning Service Contract. Improved the service our stock supplier of cleaning and operating supplies as well as our chemical supplier for Sanitation Operations. Through detail research and data analysis these changes has driven down cost for both of these areas by 30 percent. Engaged Sanitation Employees with a Behavioral Based Work approach to improve the safety of the team and minimize safety incidents within the department as well as the production facility. Through focused efforts of ensuring team members walked out of the facility daily like they walked in there were zero loss time incidents as well as no recordable injuries within the Sanitation Department for over 40 months. Implemented a shutdown checklist for production to increase the amount of detail cleaning hours for Sanitation by 35 percent and increase production capacity by 15 percent. and mentored the entire Food Safety to Level 4 for Continuous Improvement at the Irving Site. Maintain the highest Continuous Improvement Score at the site against 25 other teams. Reduced the Recordable Total Injury Frequency to 0.05 over the past 24 month period versus 10.76 over the same period of time 23 months ago. In-depth Work Behavior approach and observation of employees injured exchanging feedback on work methods and practices in effect and exchange of ideas and best practices. Reduced Chemical Expenditure Plan over $55.6k through testing caustic levels of treatment applications to meet corporate and government standards influenced the initiatives of environmentally friendly application and reduction of use of harsh chemical within the community. Generated labor saving of over $70,000 over a 12 month period through schedule adjustment for Food Safety Sanitation Employees against the Master Production Schedule anticipation shutdown times for product close out. Designed a detail cleaning plan for the packaging departments to reduce schedule downtime for maintenance and unscheduled downtime for emergency repairs. Plan has reduced the overall downtime within packaging departments by over 60 percent and increase capacity throughput by 15 percent . Increased Shift OEE productivity 27 percent against previous year's shift performance generating over $75,000 increased productivity. Implemented a Playbook Process where the exchanged of feedback from Filler Operator to Mechanic reduce the time for fault analysis and increase speed of repair. Incorporated a Sanitation Process with a focus on equipment readiness to improve weekly startups minimizing downtime for Carton Forming Machine/Box Packaging Machine Malfunctions - downtime reduced 35 percent as well as increased production capacity by 20 percent. Generated over $185,000 across the plant for weekly start-ups.
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