Wegmans Freezer Inventory Control MSD #12714

Ben WhippleEmily BurnsTim HoganBen Jilson

Today’s Agenda

Current state Customer needs Spec list Scope

Proposed Solutions Selection matrix Proposed solution sets

Risk Assessment Next Steps

Current state

Customer needs listCustomerNeed #

Importance(1 high - 3 low) Description

CN1 1Non-held finished goods should make their way to FF2 in an efficient manner,

minimizing the time spent waiting in the freezer.

CN2 2 Reduce dripping incidents in the freezer.

CN3 1 Reduce impact of dripping in the freezer.

CN4 2 Way to ensure finished goods leaving the warehouse have been recorded.

CN5 2 Way to record product has entered the finished goods warehouse

CN6 2Simple way to differentiate between cases that hold varying types of product

when coming down spiral 1 and spiral 2.

CN7 1 Increase usable space in freezer

CN8 1 Decrease need for space

CN9 2 Freezer organization that takes into account day to day variations.

CN10 1 Ability to quickly locate skid within the freezer.

CN11 2 Ability to quickly locate WIP rack within the freezer

CN12 3 Take into account changes being made for RSC3.

CN13 2 Organized storage location for quality samples while they are in the freezer.

CN14 2 Allow quality holds to be easily accessed.

CN15 2 Defined owner to provide raw materials to production

CN16 2 Defined owner to receive raw materials

CN17 2 Ensure QA holds and limited production runs are removed in a timely manner.

CN18 3 Defined owner for storage and handling of WIP

Spec listCustomer Need Spec Numerical Goal

CN1 Number of finished goods pallets not on hold <5 at any time

CN2 Reduction in # of dripping incidents >50%

CN3 Reduction in Goods damaged by dripping >50%

CN4 # of pallets not recorded < 5 a week

CN5 # pallets not recorded < 5 a week

CN6 # of cases palletized incorrectly <2 a week (How to measure?)

CN7 # of accessible pallet position 10% increase at high volume levels

CN8 Average number of pallets in freezer (weekly running average) 40% reduction

CN9 System takes into account all possible levels of demand Yes

CN10 Time to find specific skid <30 seconds

CN11 Time to find specific WIP rack <30 seconds

CN12 Take into account changes being made concerning RSC3 Yes

CN13 Organized storage location for QA Samples Yes

CN14 # QA hold pallets not accessible 0

CN15 Defined Ownership of Raw Material removal Yes

CN16 Defined Owner for Receiving raw materials Yes

CN17 Defined owner for the storage and handling of WIP Yes

CN18 Defined Owner for Holds (QA and limited production) Yes

Proposed Scope

This project is to analyze the current operating state of the Wegman's Bakery Freezer, identify process shortfalls that are contributing to the "out of control" state identified by the customer, develop and apply solutions to those shortfalls deemed to be within the control of the client, implement these solutions in a timely and cost effective manner, and develop a plan for sustaining these solutions in a way that results in an "in control" process for the foreseeable future

Proposed Solutions

Raw Materials

Proposed solution set: Raw materials Recommendations

Designated transfer spots Optimize number of racks Optimize use of racking Standard put away rules Central information board

with raw material locations White boards

Considerations Color coding scheme Colored paths More frequent orders Pallet stacking Dedicated aisles Signage Magnet boards

WIP

Proposed solution set: WIP Recommendations

Prioritize locations White boards Standard put

away/pick process

Considerations Color coding scheme Colored paths Dedicated aisles Magnet boards

Finished Goods

Proposed solution set: Finished Goods Recommendations

Show obvious signal when a QA hold can be removed

Central information board Designated transfer spots Optimize number of racks Optimize use of racking Remove café support Standard put away rules White boards Magnet boards

Considerations Signage Color coding scheme Colored paths Remove commercial support Dedicated aisles Pallet stacking Analyze effects of reefer

availability Case differentiation methods

Different colored tape (group’s choice)

Marker Stickers Different colored boxes Worker training Better labels

Proposed solution set: QA Samples

Considerations Specialized racks New containers Signage Moving storage to QA

area

Recommendations Put QA samples in

space pallets cannot fit Standardize put away

rules

Risk Assessment

Next StepsDetailed Design Phase Week 6 Week 7 Week 8 Week 9 Week 10 Week 11

Develop pallet position layout plan

Develop put away process

Analyze use of flow racks, number and process

Create Detailed Plan for implementing Case Marking

Evaluate RM order policies, determine impact, suggest optimal order frequency

Design White Board/Magnet Board use policy

Evaluate Feasibility of customer container/racking for QA samples

Define and Document processes and declare owners

Create signage and marking conventions for the freezer

Develop freezer organization changeover plan

Develop retraining plan

Evaluate effect of reefer delays of varying amounts, quantify impact

Develop Evaluation Plan, data gathering and metrics generation

Create and Deliver Detailed Design Review