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DEFINING STEPS TO MSD II TYLER BRENT BRIDGET EGGERS VALERIA GONZALEZ RICHARD LATHAM

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CONCEPTS TO KAIZENS Started with concepts Kaizen activities include our concepts Prove feasibility and practicality of these concepts Small, resource constrained, fast implementation We welcome feedback

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SCALING A DAY IN THE PROCESS Shares station w/ commercial. Cross-training evident. 4 AM Commercial Pre-Scaler comes in. 11 AM Frozen Pre-Scaler comes in. Multiple batches are pre-scaled at a time. Ingredients are stored in multiple locations. Work in process is not trackable.

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SCALING KAIZEN Add labels to pre-scaled ingredients Speeds up communication Less errors Modify cookies recipes format Less errors in scaling Easier for training. Checklist of whether ingredients are there before starting a batch Prepared if low on ingredients Can change plan earlier

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ADD LABELS TO PRE-SCALED INGREDIENTS

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REDUCE DEFECTS ON SCALING %INGREDIENTS SINGLE FULL BAGSPARTIALPROCEDURES STAGE 1 21.76Brown Sugar8485379129Cream together for 19.78Vream Rite Shortening271498504020 seconds 0.61Salt2976372.20 0.61Baking Soda0722002.20 STAGE 2 13.78Bessie Flour0848545010Add to above on high for 10.2Am. Beauty Cake Flour520460370 2 minutes STAGE 3 5.09Liquid Whole Eggs07235218.50 Add to above on high for 3 minutes 1.1Clear Vanilla Extract042752404 0.28FB Soybean Oil(buckets)326108101 STAGE 4 32.79Chocolate Chips-1000 ct088755116.67416.67Add to above on mix thoroughly on high for 1 min 90 COOKIES PER CASE 100TOTAL: 360.57 Cookie Pucks no Nuts

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CHECKLIST OF WHETHER INGREDIENTS ARE THERE BEFORE STARTING A BATCH

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MIXING A DAY IN THE PROCESS Shares with commercial. Deviation between types. Average cleaning time: 12 minutes Labor driven process Average process time and Actual vs. Scheduled:

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MIXING KAIZEN Have all boxes opened before being placed beside the mixer Faster once on the mixer Scale liquids (eggs, vanilla) ahead then store in pie room Faster once on the mixer Break down ingredient boxes after all mixing is complete Reduces mixing cycle times Tracking sheet for mixer Tracking improvement for system

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MIXING KAIZEN Mixer schedule located by the mixer Other lines know when mixer is available Material handler knows when materials are needed at the mixer After mixing, operator takes all unused ingredients away and checks schedule to see if any will be need for next product Speeds up next product Can be done by other employees Assign roles to material handler to collect and return ingredients Speeds up machine downtime Relieves mixer operator of extra work Have mixer operator do sanitation on mixer Reduce downtime for mixing changeovers

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MIXING KAIZEN Get a 3 rd commercial trough Less downtime on mixer Have all ingredients put into one bucket so no box opening while on the mixer Faster once on the mixer Different boxes to receive ingredients in, easier to open Faster to open and break down

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DIVIDING A DAY IN THE PROCESS Shared with doughnuts, muffins, etc. Average actual run time: 2 hrs and 33 mins Start time: Min 5:49 pm Max 8:14 pm Avg 6:52 pm

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AVERAGE DOWNTIME:

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DIVIDING KAIZEN Reassign roles for dividing staff Reduces dividing downtime Change type of wire Will break less often Ensure machine is setup on time Maximize available time for dividing One type of machine per day Changeover time doesnt interact with operation time

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SYSTEM A DAY IN THE PROCESS Frozen Cookies Commercial Cookies

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SYSTEM-LEVEL KAIZEN (METHODS) Update schedule with more accurate times Schedule will reflect actual better. Add changeover time into schedule Schedule will reflect actual better. Offset break schedules so another operator can run mixer increased utilization of mixer Add in breaks of workers into schedule if breaks cannot be offset more accurate scheduling and planning of resources Start commercial mixing earlier in the day Frozen cookie mixing should have less late starts Create standard work best and fastest way, reduces variability

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SYSTEM-LEVEL KAIZEN (METHODS) Run commercial cookies with butter on a different day than frozen cookies with butter more soft butter available, less nearby inventory Mix sheet cookies the night before more mixing time available A way to know if there is enough time to do more batches for the night get ahead for the next day, not run late Have schedule of spiral 2 and commercial oven line up better Scheduled Production = Actual Production, Reduce variability Make communication board Everyone knows what is going on. Improve tracking board for management Everyone knows what is going on.

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SYSTEM-LEVEL KAIZEN (MAN) Packaging workers come help with dividing Dividing downtime reduced Divider workers come help with mixing Mixing downtime reduced Add more cross training Flexible staff to work different processes.

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SYSTEM-LEVEL KAIZEN (MACHINE) Fix frozen troughs and redesign to stop future problems Safer and easier workflow