Fine Organics LimitedChris Steel

Continuous Improvement Manager

12th May 20111

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

2Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

Company / Site History

1977 Company founded on Peterlee site1984 Laporte acquired controlling interest1984 New Seal Sands Site opened1985 MPB-1 commissioned 1986 MPB-2 commissioned1989 MPB-4 (Pilot Plant) commissioned 1996 MPB-3 commissioned 1998 R&D & QC laboratories opened2001 Laporte acquired by Degussa 2007 Changed name to Evonik2008 (Nov) Management Buy Out

Fine Organics Limited (Fine Industries)

2011 What’s next ???????

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

Fine Organics

4Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

Fine OrganicsManufacturer 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 care

FDA inspected site

5Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

Core Values

SHEQFully 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.

Change and innovation We will pursue opportunities for our

business, our customers and our people without compromising SHEQ standards.

Customer care

Continuous ImprovementSustainable Quality, Cost and Delivery, targeting best in class & demonstrating operational excellence in all that we do.

Fine Organics Limited

“Where are you on the never ending road towards excellence?”

12th May 2011.

Chris Steel

Continuous Improvement Manager

How did we get from this…….

7Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

to this………

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From this……..

9Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

To this…….

10Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

From this……..

11Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

To this…….

12Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

From this……..

13Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

To this…….

14Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

15Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

August –Jan 20116 months @ 100%

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Jan 20118.5 Stock Turns

17Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

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”

Peter F Drucker

“There is nothing so useless as

doing efficiently that which should

not be done at all”

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“90% of all improvements are common sense, it’s having a structured approach to implementation

that counts ” Chris Steel

We started on our Journey in Jan 2007

• Decided where you are and where

you want to be?

Policy

deployment

Bench Mark

Training

Funding / Partners

Cultur

e

Which vehicle do you use?

Who’s on the journey?

• Senior / Middle management• Operational Staff• External Help!• A driver

Dedicated facilities

22Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

What tools do we use?

5 S7 Wastes

Visual managementStandard Operations

Lean Toolbox

Policy Policy DeploymentDeployment

What Type of

Tool Box ?

24Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

Friday, April 21, 2023 24Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

Linked to the (BMS) Business Management System

MPB4

OEE Data capture

Batch card

BMS

CPOT

At home

In the office

On the move

BMS

KPI’s

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”

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So where next for us?

26Fine Organics Limited, Seal Sands, Middlesbrough, UK, TS21UB

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

Fine Industries Ltd: An innovative group

to create value for its customers.

Continuous Improvement

“a way of life”