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TRACC J URNEY HEINZ
Over a century ago, Heinz founder Henry John (H.J.) Heinz created a foundation for company success by instilling the values of team building, collaboration, innovation, vision, results-based operations, and integrity in his employees. These values are still in evidence as demonstrated by the introduction of the Heinz Global Performance System (HGPS) — a standardised global continuous improvement programme powered by TRACC.
The Heinz journey to world class has been designed as a five- to seven- year process to allow each site to determine its own rate of progress. Bent on planning, innovating and navigating activities for sustainable long-term success, Heinz researched a system that would allow global standardisation of its operations excellence processes, while also allowing regional implementation flexibility. In short, it needed a system that would enable best practice management across multiple plants, and integrate its regional/local improvement initiatives, such as Six Sigma, Lean, WCO, TPM and SCO. After researching approximately 40 consulting firms around the world, Heinz finally decided on the TRACC Value Chain Solution, because of its proven success with some of the world’s most recognised organisations including SABMiller, MillerCoors, DuPont, Kellogg’s, and Coca-Cola (bottling partners).
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Developed over 18 months, the HGPS integrates Heinz’s global supply chain by better leveraging direct and indirect procurement, rationalising the manufacturing footprint, and driving operations excellence initiatives. The HGPS marks the transition from a production system to, what Heinz termed, a ‘performance’ system. The advantage of this is that it pulls together the entire supply chain into one standardised continuous improvement approach that everyone can follow, at their own pace, on the journey to becoming ‘world class’. (Business Excellence Magazine, June 2010) All the elements of world class manufacturing, procurement and logistics are sequenced in the HGPS, and progress is monitored and measured every step of the way. The Heinz journey to world class has been designed as a five- to seven-year process to allow each site to determine its own rate of progress.
TRACC MILESTONES End 2008
Heinz seeks to combine its most successful tools and processes into one production process called the Heinz Global Performance System (HGPS). The organisation selects TRACC as the digital platform to drive the HGPS, comprising 10 TRACC Operations Best Practices in 14 international languages.
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“Any initiative will always have its share of doubters, but the response from employees has been remarkable. Heinz has a mixture of union and non-union factories, and the unions have been fantastic.” — Gary Thomas, Vice President, Global Technical Services
2009
The Heinz Board of Directors approves the roll-out of the HGPS to eight global production plants — four pilot sites in North America and one site each in Spain, Italy, the UK and the Netherlands.
2010
Due to this cross-country, cross-cultural implementation, TRACC is rolled out across Heinz Europe in seven languages: English, Dutch, Spanish, Italian, Polish, Russian and German. The HGPS is extended to nearly 30 plants. Note: Competitive Capabilities International (CCI), the people behind TRACC, was honoured with a Heinz Supplier of the Year Award in 2010 — a significant endorsement of the TRACC brand.
2011
The HGPS now provides the means to standardise measurement, reporting and continuous improvement practices across all the North American plants as well as 21 facilities in Europe, 27 in Asia/ Pacific and nine others, bringing the total number of plants to 81.
HIGHLIGHT Heinz ranked first in overall customer satisfaction among 225 companies in 47 industries in the 2011 American Customer Satisfaction Index. The success of the HGPS played a large part in this achievement.
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2012
The Heinz Pudliszki site in Poland becomes the first site within Heinz to reach Stage 3 in the seven Foundation TRACCs — Leading and Managing Change, Human Capital, Teamwork, 5S, Visual Management, Environment, Health and Safety, and Focused Improvement. Australian Business Magazine BRW names HJ Heinz Australia one of the 30 most innovative companies because of its culture-changing HGPS and productivity generation.
2013-present
To encourage best practice sharing between sites, a workshop is hosted in the UK in 2013, where all CI managers from all EU regions meet to discuss quick wins and shared learning. These multi-day workshops have now become the norm, and will be hosted once or twice annually. Additionally, best practice teams (comprising representatives from sites across Europe), work together frequently.
HIGHLIGHT Heinz Pudliszki’s pilot area (TK5) was awarded the TRACC Foundation Award and was commended for reaching Stage 3 in the Foundation TRACCs. The pilot area also recorded an impressive 25.5% improvement in Overall Equipment Effectiveness (OEE).
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