CORPORATE CAPABILITY STATEMENT - Willow

Transcription

Willow Ware Australia Pty. Ltd.
60 Annandale Road, Melbourne Airport VIC 3045. A.B.N. 55 004 316 027 tel. 03 8346 0400 fax. 03 9338 6741 web. Willow.com.au
CORPORATE CAPABILITY STATEMENT
Brief Description and History
The Company history is extensive, spanning over 125 years
and covers much of Australia’s modern economic history.
Ralph and Richard Wilson commenced the business in July
1887 from seed capital given to them by their father (also
named Ralph). In its early days the business manufactured
jam, sauces and food closures. From these humble
beginnings it grew to become a provider of general metal
housewares. During the Boer, First and Second World Wars
it was a provider of ammunition boxes to the Australian war
efforts.
Through its metal manufacturing, Willow made iconic items
such as the billycan, mess tins, the Coolgardie meat safe,
bakeware, decorated cake tins and canisters and on to the
ubiquitous TV tray-table. A metal printing lithographic
department was established in 1902, which carried the
business through until the 1980’s.
In the late 1950’s the Company ventured into plastics producing baby baths, fluidized bed plastic
coating of wire handles through the process of vacuum drape forming. In the 1960’s injection moulding
was introduced, followed by and blow and foam moulding in the 1970’s. During this time, the
technology to manufacture “Heat Beads” barbeque fuel through brown coal was developed and by the
late 1980’s Willow had branched out to become the largest deer farmer in Australia.
The Company consolidated its efforts into injection and blow-moulded products during the 1990’s and
moved to a new state of the art facility located at Tullamarine in 2003.
Willow is now one of the largest privately owned Australian plastics
manufacturers. We manufacture and market Willow and Starmaid
branded products for all major retailers and are a key automotive
supplier to Toyota Australia.
Business Turnover
Year ending 30th June 2013
$55 million
Type of Business, and Industry Sector
Willow is an Australian housewares manufacturer, principally of injection and blow moulded plastic
consumer products with automotive industrial production for Toyota Australia.
Page 2 of 19
Corporate Governance at Willow
The Board of Directors has adopted the principles of good governance as prescribed by the ISO 8000
Good Governance Principles. Policies and procedures have been implemented to ensure a culture of
good governance is practiced to the benefit of shareholders, management, employees, customers,
suppliers and the broader community.
There is a strong ethical business culture at Willow, practiced on a day-to-day basis. We have a
documented Governance Model that covers more than 30 major policy items. The statements of
Vision, Mission, Aspiration, Values and Style, as well as the strategic and corporate planning
processes, are integrated within this.
The CEO delivers regular education, culture and governance sessions. We practice the maxim of
walking-about and engaging with all our people – particularly those on the shop floor.
Willow’s Good Governance Model
-
Good Governance Policies
Heritage
Culture & Values
Strategic Plans & Budgets
Business Systems
Key HR Policies
Products
Safety Management System
Quality Management System
Environmental Management System
Risk Management
Compliance
Corporate Social Responsibility
The Strategic, Financial, Operational and Tactical Planning, Execution and Reporting Cycles
The Strategic Planning cycle commences in
October each year with the development of
the strategic and corporate plans.
Operational performance is assessed and
remedial actions assigned at each daily Endof-Shift Meeting, at the weekly Operations
Meeting and monthly Sales and Operations
(S&OP) meeting.
Willow’s Strategic Planning Process
Page 3 of 19
End-of-month Profit & Loss and Balance Sheet
results are issued by the end of the second
working day of the new month. Each
department reports progress monthly
according to a balanced scorecard and KPI
summary. These are tabled as department
end-of-month kits.
Willow’s Planning Cycle
Business Functions and Departments
Willow operates a fully integrated manufacturing enterprise comprising;
 Sales and Marketing,
 Customer Service,
 Supply Chain and Distribution,
 Purchasing and Master Scheduling,
 Industrial Design,
 Manufacturing,
 Engineering,
 Information Technology,
 Finance and,
 Human Resources.
Operating Environment: Operations, Competitors and Customers
We operate 3 shifts over 24 hours, 5 days per week. Our business competes heavily against the
cheaper labour countries of China, India, Central Asia, New Zealand and the USA. We buy from
oligopolies (the petro-chemical and cardboard industries) and sell to the major retailers Woolworths
Ltd. (Woolworths, Safeway, BigW, Masters and Danks); Westfarmers Ltd. (Bunnings, Coles
Supermarkets, Kmart, Target, Bi-Lo, Officeworks); Metcash (IGA and Mitre10), Supercheap Auto,
Blackwoods and Aldi as well as loyal independent state customers.
Major Facilities and Technologies
Willow’s manufacturing site at Tullamarine was
purpose built as a green-field world-class facility in
2003. The main facility comprises inwards goods,
engineering, production and warehousing of 15,000
square metres, the distribution centre is a further
8,000 square metres, in all a total of 23,000 square
metres.
We use blow moulding, injection moulding and
expandable polyurethane manufacturing processes
comprising about 65 machines.
Willow’s Tullamarine Factory
We provide full in-house design, marketing, sales,
manufacturing, engineering, logistics and distribution
competencies Australia wide and for export.
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Products
We market approximately 400 products comprising the following strategic business units:
 Leisureware (Coolers, Jugs &
 Storage
Accessories)
 Bakeware (Traditional, Non-Stick,
 Laundry (Buckets, Basins,
Heavy Metal & Silicone)
Pegs, Hampers & Baskets)
 Refuse (Indoor & Outdoor)
 Housewares and gadgets
 Carry Cans (Fuel & Water)
 Automotive
Examples of Willow Product Range
Operational Systems
Willow uses the following world-class methodologies to build an integrated operating system;
1. Strategic Visioning and Planning,
2. Balanced Scorecard Reporting,
3. Business Excellence (ERP & MRPII Class A),
4. Total Productive Maintenance (5S and TPM),
5. ISO 8000 Good Corporate Governance,
6. AS 4801 Safety Management System,
7. ISO 9001 Quality Management System,
8. ISO 14000 Environmental Management System, and
9. ISO 31000 Risk Management.
Page 5 of 19
Workforce Profile
Willow’s People December 2012
Our workforce comprises people working in
both the office and shop floor. We have
approximately 200 people working for Willow,
representing more than 20 nations. Our
longest serving person has been with the
Company for 40 years and 45% of our people
have completed 10 years of service or more.
We have a variety of skills and experience specializing in Design, Engineering, Marketing,
Sales, Accounting, Human Resources,
Manufacturing/Production personnel, Die
setting, Fitters & Turners, Electricians and
Toolmakers.
HR Initiatives
We have undertaken considerable investment in our HR strategies and offer industry best practice in
employee relations, benefits and engagement, examples being;
1. Upper quartile levels of remuneration for staff,
2. Flexible work arrangements are considered and practiced,
3. Superannuation back paid from 1964 for those eligible at the time,
4. Superannuation currently paid at 10% (legislated rate is 9% SGC),
5. Professional education and development,
6. A long-term employment ethos,
7. Staff 2 week bonus-leave program,
8. Early entitlement provision to Long Service Leave,
9. Staff attitude/morale surveys and
10. Paid maternity leave scheme
Engagement of Our People
The following initiatives have been implemented to promote a harmonious workplace
 Discount purchases of product,
 Service awards recognition,
 Hearing checks,
 Employee Assistance Program
 Active Wellness Program and CSR Committee
 Event celebration employee barbecues:
o Christmas Break-up
o AFL Grand Final
o Melbourne Cup
 Flu vaccination program,
Page 6 of 19
Strategies to Engage Our People: “The Willow Way”
“The Willow Way” is an exciting concept that is being implemented to provide creative methods to
communicate to all our people both in the office and on the shopfloor. The goals of the program are to
build pride, disseminate the aims and aspirations of the Company and provide a conduit that
encourages the celebration of the successes and professionalism of our people.
The “The Willow Way” program is in its formative stages and has commenced with the following
initiatives;

“Stop” safety campaign.

Company’s aspirations campaign.

Refurbishment of notice boards and signage for;
 Fire Extinguisher Stations,
 Cleaning Stations,
 First Aid Stations located on structural posts throughout the factory.

New masthead for the monthly Willow newsletter.

Internal Company literature in booklet form for the CEO’s monthly addresses.

125th Anniversary celebration DVD.
Quality Management System and Practices
In 1991 we embarked on a formal approach to address and
underwrite quality by commencing Total Quality Management (TQM)
with the Phillip Crosby organisation. This was implemented over an
initial four-year period covering all staff and shopfloor personnel. In
1999 we received the Quality Beacon Award from them for our
commitment to quality and continuous improvement. In 2000 we
were accredited to ISO9001 Quality Management System through
SAI Global.
Page 7 of 19
Safety Management Model and Practices
Safety awareness and accident prevention is paramount and is taken seriously by all management,
and people in the office and on the shopfloor. The safety message is delivered at formal in-house
training sessions, through the monthly Willow News and at end-of-shift toolbox talks.
Samples of In-house Safety Campaign
We received our first 5 Star grading with NSCA in 2004 and our initial AS
4801 Safety Management System accreditation through SAI Global in 2008.
Page 8 of 19
Environmental Management System and Practices
The move to our new purpose built site at Tullamarine in 2003 helped us commit to and achieve
environmental leadership behaviours for our industry. Maximum effort is given to the recycling of;










Aluminium cans from use in the canteen,
Used postage stamps,
Shrink wrap,
LDPE and HDPE plastic lumps from purging and ABS styrene,,
Cardboard packaging,
Scrap metal,
Scrap pallets,
Used printer cartridges, scrap and shredded paper, and
General recycling from our canteen.
Rejected products are recycled directly back into the production process
We received ISO 14001 Environment Management System accreditation through
SAI Global in 2007.
Our environmental management plans include;
 Reduction of our impact on carbon emissions through the installation of 4
wind turbines to generate up to 10% of our electricity needs.
 Installation of a 250,000-litre water tank for rainwater harvesting to reduce
and potentially eliminate, our use of mains municipal water.
 Reduction in our levels of rejects and wastes arising from the manufacturing
process.
 Beautification of our parks and gardens to reduce reflected heat in summer
by 1 to 2 degrees and provide a pleasant environment to promote the
wellness of our employees.
 Continual environmental education programs for our employees.
.
Willow’s
Willow’s 250,000L
250,000L Water
Water Tank
Tank
Willow’s Wind Turbines under beta test
Page 9 of 19
Innovation
Innovation has been a corner-stone at Willow commencing with the manufacture of sheet metal
machinery in 1887 then onto the innovation of oval product tooling, the first Australian manufacturer to
adopt the Henry Ford conveyor system, the mass production of ammunition boxes from unique
machinery the design of which was adopted by ammunitions suppliers in the UK and USA during the
war effort, hot-dipped tinning and galvanising, the lithographic reproduction of original art for metal
houseware products commissioned from some of Australia’s leading and renowned artists, expanded
foam styrene, the invention and manufacture of Willow “Heat Beads” barbeque fuel and more recently
the installation of rainwater harvesting to reduce and potentially eliminate our use of mains water, the
planned installation of 4 noiseless wind turbines to generate up to 10% green electricity for our
manufacturing needs and the implementation of an illustrative visual strategic planning documentation
and monthly reporting process that is delivered in the same illustrative format from the board room
through all management ranks and onto the shop-floor.
A listing of the innovations developed and implemented by Willow over the years appears in the
following table:
YEAR
1887
INNOVATIONS
Foodstuff:
The production of jams and preserves from the proprietors’ own recipes at Wilson’s Lane, North
Melbourne.
1887
Sheet Metal Machinery:
Design and making of machinery to produce square containers for dry food, prior to the introduction
of end roll seaming technology.
1890
Lithography:
The first lithographic flat bed (off stone) tin printers in the colony of Victoria and perhaps in Australia.
N.B. This is in dispute still with the descendants of J. Gadsen Pty. Ltd.
1924
Oval Product Tooling:
The construction of tooling for oval products by the design and building of a lathe chuck which moved
the tool steel through the long and short axis on each revolution, the chuck movement induced by
gravity and governed by a friction controlled back plate.
Tools for oval trays:
- Canisters,
- Boilers, and
- Baby baths
This was well before the days of programmable milling machines.
1932
Conveyor System:
The first Australian manufacturer to adopt the Henry Ford Conveyor System. The belt was 50cm
wide and 60 metres long running to the spray painting department from the assembly department, it
was canvas.
1938
Horses:
The breaking in, training and breeding of horse teams to deliver our manufactured goods in time of
petrol rationing during World War II.
Page 10 of 19
YEAR
1939
INNOVATIONS
Army Bullet Boxes:
The invention of an amended product design and the required machinery to increase the quality
and production of .303 ammunition bullet boxes.
These new boxes, the H26 and H52, replaced the H13 handmade box and lifted the daily shift
output from 150 to 1,100 units.
The automatic and seaming machine replaced the labour intensive hand soldering. This machine
was conceived by our company and the Melbourne machine builder W.G.Goetz that was
instructed to build it despite their warnings that it would break and their refusal of warranty. We
went ahead at our own risk, successfully. As a munitions manufacturer it enable our supply to
meet the demand.
1940
Galvanising and Tinning:
As a munitions supplier of hot dipped galvanised and tin products, we were the first to replace
Sulphuric Acid with Hydrochloric Acid as a less dangerous pickling.
1940
Infra Red Spray Paint Drying:
The installation of a conveyor infra red drying oven for spray painted enamels used in munitions
work, this technology was installed as an innovation to replace the less reliable convection drying
system.
1944
Machinery:
Designed and built wire cutting and forming machinery, lap seam soldering machines (basin
seams), tapered can body forming and soldering machines (billy cans) in times of no supply of
design and build machinery from machinery manufacturers.
19521980’s
1955
Art Work:
The first to commission and introduce iconic artwork into tinplate kitchenware from:
- Septimus Power
- Rubery Bennett
- Pro Hart
- Maynard Waters
- Raymond Ward – Thompson
- Photos of Royal occasions et alia.
Metal Press Adaption:
The first to incline 100 ton heavy duty durable action metal drawing presses to use gravity to exit
the pressed piece and more importantly to keep the operator’s hands outside of the machine.
1958
Artwork Massed Designs:
1960’s
The first to produce sets of decorated kitchenware with artwork covering the whole sheet with a
design repeating both horizontally and vertically, as a “massed design”.
It enabled components (lids on bodies) to be cut at random to give a uniform appearance over a
whole set.
This resulted in improved efficiency and lower cost by:
- One set of artwork and printing plates instead of eighteen
- At least doubling of the printing and processing efficiencies.
Expanded Foam Styrene (EPS):
Design and building of machinery and moulds for expanded foam styrene mouldings for
packaging and consumer products.
Commissioning licenses in South Africa and New Zealand who imported our machinery and
moulds, paying annual royalties.
1960’s
Linked Processes:
The strategy to design or prefer consumer products, which utilised a number of our varied
Page 11 of 19
YEAR
INNOVATIONS
production facilities. For example:
1960’s
- Pedal bin kitchen tidy
- Metal roller coating (lid)
- Metal lithographic printing (body)
- Wire forming (pedal mechanism)
- Injection moulding (pedal and inner)
- Cooler chest (eskies)
- Metal lithographic body
- Wire framed handle
- Injection moulded inner
- Blow moulded lid
- Expanded foam styrene insulation
Heat Beads:
The production of “Heat Beads” – a barbeque fuel from Yallorn (Vic) brown coal char.
We designed the blending formula and the rotary beading press.
1970
Ultra Violet (UV) Ink Drying:
U.V ink drying for high-speed lithographic printing, replacing capital and space intensive diesel
fired convection ovens.
1980’s
U.V Ink Drying:
Installation of 4,000 sheets an hour, wax spray dry lubricant on tinplate sheets prior to cutting
and deep drawing to eliminate oiling and degreasing.
1980’s
Plastic Foils:
The first to apply artwork decorations for injection-moulded housewares by fusing artwork
printed on thermoplastic foils onto the parent product during the moulding process.
The artwork (e.g. camellia – floral) was grown, photographed and then printed on foils and on
metal for a complete integrated range of plastic and metal housewares, which strategically
played to our own strengths.
1985
Primary Industry:
Farmed deer, galloway cattle, water buffalo in Gippsland not only as a protective financial
fallback but also as an unique investment, which would command premium prices.
The deer herd worked up to 1,200 head to be the last in Australia, comprising of the species
rusa, sambar, red and fallow (brown, menil and white) versions were sold to Australian markets.
Frozen “velvet” antler was sold to Asian markets as an aphrodisiac.
The exploratory and successful hybrid of the large Sambar and the Red yielded a fertile hybrid,
high venison and velvet-producing deer.
2010 –
2011
Engineering & Production:
1. The development of an “over- moulding” system, comprising of two latest generation
injection moulding machines and an overhead robot. This relatively new technique
within the plastic industry enables us to produce high end quality products not done by
anyone else in Australia. The process is fully automatic and can produce up to 1500
over-moulded products per shift.
2. Two fully automatic production lines for automotive ducts, comprising in-blow moulding,
two robots, de-flashers, trimming devices and a re-grind system. Designed in house,
this process is unique as it is very rare to have an automated process associated with
blow moulding. This is due to the lack of precision normally associated with the blow
moulding process. Once again, this process has enabled us to become more productive
and eliminating the safety risks associated with manual handling. This successful
process has increased our cycle time by 32%.
Page 12 of 19
YEAR
INNOVATIONS
3. The research and development, prototyping and production of 47 jigs, tools and
guillotines for automotive ducts. These new machines were designed in-house when
Willow became a tier one supplier to Toyota. In a first for the automotive industry in
Australia, all the new model parts are cut by guillotine and not saws. The advantages of
this new system has resulted in the elimination of dust created by traditional saw
blades, a great improvement in the dimensional tolerances of the part, a 70%
improvement in cycle time and the elimination of safety risks associated with the
original process.
4. Close loop regrind recycling system. This was designed by our engineering team to
ensure that all our regrind goes to the centralized regrind station. This assists with
housekeeping, but also ensures that all HDPE resin is automatically recycled during
production process.
5. Centralized regrind recycling station. All excess plastic is reground at this station. This
process has enabled us to reuse our main resins Polypropylene – PP- and high density
poly ethylene – HDPE- thus enabling us to be more efficient by using up to 100% of
reground material in some of the products we are producing (i.e. Traditional 60L and
75L Willow bins), making us more productive and environmentally friendly.
6. Special purpose automatic devices designed and build in house, I.e. Punch, clip
applicator and check device. This device completely eliminates any safety risk and
increases efficiency by having a fully automated process
2011
Product Design
The development of the first Kitchen Tidy that has a dual action Touch Top and Lift up Lid with
a rubbish bag retention system. The “Clipaway” Touch Top Tidy was a winner in the 2011
Victorian Design Awards.
2012
Product Design
Using previously untried technology, we were able to develop a “telepac” that could be
manufactured using a blow moulding technique. This product is used for the medical
sterilization of cameras used in operating theatres. We were then able to extrapolate this
technique to use as a new manufacturing method for our existing fuel can nozzle. This not
only improved the function of the product, but the productivity was also improved.
2013
5L Alpine Jug
The Alpine Jug is one of our iconic products and was redesigned to give it a new look. It is
now produced so that it can be made in 2 colours. The production line has been automated,
improving both safety and productivity and the tap has been redesigned to remove the
possibility of the jug leaking.
Page 13 of 19
Significant Achievements
We have attained significant achievements, evidenced by:
1. Over 125 years of continuous manufacturing operations in Australia by the one family line; a
family business practicing strong family values.
2. Strong sales growth.
3. Superior customer service at 99%.
4. 90% range manufactured in Australia.
5. Strong recent employment growth.
6. Adoption of best practice methodologies.
7. Recognised in the Powerhouse Museum.
8. Quality, Environment and OH&S accreditations.
9. Extensive history and current innovative practices.
10. Strong community spirit by supporting local council community programs and working closely
with a local disadvantaged primary school.
11. 48 industry, customer, safety, environment, export and product awards.
12. Innovative employee engagement program called “The Willow Way”.
Powerhouse Museum
We have been honoured with the Selection Award from the Powerhouse Museum for our 35-litre
cooler. The Powerhouse Museum is a museum that builds a collection of Australian manufactured
products that are culturally significant to the Australian way of life. Over the years, we are proud to
have received 14 such entries in this significant museum.
Awards Recognition
Willow has received 48 awards and recognitions since 1972 in the fields of; design, manufacturing,
safety, environment, supply, and export.
Year
Award
Result
Awarded By
1.
2013
Design Manufacturer – Made in Melbourne
(Willow Leisureware Products)
Winner
Melbourne Design Awards
2.
2013
Sustainability & Environment Award
Winner
Hume City Council
3.
2012
Product Design – Consumer
Winner
Sydney Design Awards
4.
2012
Best Solution of an OHS Workplace Risk
Certificate of
Merit
NSCA
5.
2011
Business of the Year
Winner
Northern Business Achievement Awards
6.
2011
Human Resources Award
Winner
7.
2011
Sustainability and Environment Award
Winner
Page 14 of 19
Year
Award
Result
Awarded By
8.
2011
Systems Excellence Awards – Integrated System
Winner
SAI Global
9.
2011
Victorian Business Awards - Manufacturing
Finalist
The Age - Dunn & Bradstreet
10. 2011
Corporate Social Responsibility
Award
Hume City Council
11. 2011
Product Design - Consumer
Winner
Melbourne Design Awards
12. 2010
Systems Excellence Awards – OH&S
Winner
SAI Global
13. 2010
Systems Excellence Awards - Quality
Finalist
SAI Global
14. 2010
Systems Excellence Awards – Environment
Finalist
SAI Global
15. 2010
Systems Excellence Awards – Integrated System
Finalist
SAI Global
16. 2010
National Awards Program, 4th Generation and
Beyond, Best Practice
Winner
Family Business of Australia
17. 2010
State Awards Program (Victoria and Tasmania),
4th Generation and Beyond, Best Practice
Winner
Family Business of Australia
18. 2010
Australian Business Award – Enterprise,
Commercial Success and Sustainable Growth
Winner
Australian Business Awards
19. 2010
Environmental Sustainability
Award
Hume City Council
20. 2010
Selected in “Insights to Excellence” Showcase
Manufacturing Site
Showcase
Site
i2e on behalf of the Manufacturing Hall
of Fame; Victoria Department of
Innovation, Industry and Regional
Development
21. 2010
Manufacturing Hall of Fame
Finalist
Victoria Department of Innovation,
Industry and Regional Development
22. 2010
Lifetime Achievement – Ralph Wilson (Senior)
Finalist
Manufacturers’ Monthly Endeavour
Awards
23. 2009
Promotional Excellence
Silver
APPA (Australian Promotional Products
Association)
24. 2008
Supplier of the Year – Hardware
Winner
BigW
25. 2006
Powerhouse Museum “Selection” - 35 Litre
Wheelie Cooler
Award
Powerhouse Museum
26. 2006
Australian Design Award - 35 Litre Wheelie
Cooler
Award
Australian Design Awards, Standards
Australia
27. 2006
Australian Design Mark - 35 Litre Wheelie
Cooler
Award
Australia
Page 15 of 19
Year
Award
Result
Awarded By
28. 2005
Best Company Environmental Performance
Winner
Melbourne Airport Authority
29. 2005
Small Business Award for Outstanding
Achievement in Greenhouse Gas Abatement
Award
Australian Government, Department of
Environment and Heritage, Australian
Greenhouse Gas Office.
30. 2004
Best Solution for an OHS Specific Workplace
Risk
Winner
NSCA Telstra National Safety Awards of
Excellence
31. 2004
Certificate of Excellence for Environmental
Management
Award
Melbourne Airport Authority
32. 2004
Best Implementation of an OHS Management
System
Finalist
Excellence
33. 2004
Australian Design Award - Snaith Classique
Collection 2nd Wave
Award
Australia
34. 2003
Australian Design Award - Snaith Classique
Collection 1st Wave
Award
Australia
35. 2002
Best Implementation of an OHS Management
System
Finalist
NSCA Telstra National Safety Awards
for Excellence
36. 2001
Achievement Award in OHS Participation
Winner
Excellence
37. 2001
Best Non Food Exhibitor
Winner
Foodland Associated Ltd. (FAL)
38. 2000
Beacon Light Award for Commitment to Quality
Management and Zero Defects
Award
Philip Crosby, Crosby International
(USA)
39. 1998
Supplier of the Year - General Merchandise
Winner
Kmart Australia
40. 1998
Recognition and Appreciation - 25 Years Service
Award
Kmart Australia
41. 1988
Certificate for Manufacturing Excellence
Award
NSW Government, Department of
Industry and Trade
42. 1988
Certificate for Manufacturing Excellence
Award
Victorian Government, Department of
Industry and Trade
43. 1991
Best Variety Display: FAL Expo
Winner
Foodland Associated Limited
44. 1987
Industrial Design Award - Microette Microwave
Cookware 2nd Wave
Award
Australian Industrial Design Council
45. 1987
Industrial Design Award - Microette Microwave
Cookware 1st Wave
Award
Australian Industrial Design Council
46. 1987
Australian Manufacturing Excellence Award –
Winner
Australian Retailers Association
Page 16 of 19
Year
Award
Result
Awarded By
General Merchandise Category
47. 1974
Award of Appreciation - 50 Years Service
Award
Woolworths Limited
48. 1972
Export Award for Outstanding Export
Achievement
Winner
Commonwealth Department of Trade
and Industry and the Associated
Chambers of Manufacturers of Australia
Some Best Practice Benchmarks Practiced at Willow
ERP and MRPII Measures
Target
Customer Service
98%
Forecast Performance Accuracy
100% +/-10%
Sales Plan Performance
100% +/-10%
Inventory Performance
100% +/-10%
Inventory Record Accuracy
95%
Supply Delivery Performance
95%
Hours Lost Against Schedule
<5%
Breaks In Production Plan
<5%
Productivity and TPM Measures
Tool Change Performance
100%
5 S Non-conformances
Reduction
Equipment Failure Losses
<1%
Set Up Losses
<1%
Idling and Minor Stoppage Losses
<1%
Reduced Speed Losses
<1%
Defects
<1%
Reduced Yield
<1%
Overall Equipment Efficiency
85%
Quality Measures
Rejects
<2%
Customer Complaints
Reduction
Quality Alert Instances
Reduction
Page 17 of 19
Quality Measures cont…
Order Picking Errors
Reduction
Safety Measures
Target
Compliance to Laws, Regulations, Contractual Obligations
100%
Number of OH&S monthly surveys conducted per month
% of survey non conformance items completed
9
Target 100%
Reduction of work cover premiums
10%
Reduce Lost Time Injury rate by 10% from 2010 Year End
1.26
Reduce First Aid Injury Rate by 10% from 2010 Year End
31.59
Willow Observation Tours conducted per month (Management /
Supervisors)
8
Number of Near Miss / Hazard Reports submitted per month
5
Internal Management Safety System Audits per month
1
Zone Leader System and Core Competency Training Modules
2 topics per month
Safety Education / Training topics delivered per month. (WDC,
Engineering, Production)
2 topics per work group
Environmental Measures
Waste
-
Used postage stamps (number donated)
-
Shrink wrap - LDPE (Tonnes)
Reduction
-
Plastic lumps - HDPE & PP (Tonnes)
Reduction
-
Cardboard packaging (Tonnes)
Reduction
-
ABS Styrene (Tonnes)
Reduction
-
Scrap metal (Tonnes)
Reduction
-
Scrap paper (Tonnes)
Reduction
-
Used printer cartridges (Tonnes)
Reduction
-
Scrap pallets (each)
Reduction
-
Landfill Bins (Tonnes)
Reduction
Increase
Resources
-
Electricity Usage (kwhs)
Reduction by net 10%
-
Natural Gas Usage (gjs)
-
Automotive - Petrol (L's)
-
LPG Usage (kgs)
-
Water Usage (L’s)
Nil
Page 18 of 19
Financial Measures
Number of days taken to issue P&L Report and B/S Statements after end
of month.
2
Profit and Loss Report and Balance Sheet Analysis
5
Number of debtors and creditor days outstanding
42
Page 19 of 19

CORPORATE CAPABILITY STATEMENT - Willow

Transcription

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