DEFINING STEPS TO MSD II TYLER BRENT BRIDGET EGGERS VALERIA GONZALEZ RICHARD LATHAM.
Wegmans Frozen Cookie Capacity Increase Final Project Presentation Richard Latham, Bridget Eggers,...
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Transcript of Wegmans Frozen Cookie Capacity Increase Final Project Presentation Richard Latham, Bridget Eggers,...
Wegmans Frozen Cookie Capacity Increase Final Project PresentationRichard Latham, Bridget Eggers, Tyler Brent, Valeria Gonzalez
A DAY IN THE PROCESS
Frozen Cookies
Commercial Cookies
Problem Definition
Current state High variability in and around
the production line
There is a bottleneck at mixing
Underutilization of resources
Staffing issues
Need for overtime
Lack of standardization
Production delays
Target state Establish synchronized flow
between scaling, mixing, dividing,
and packaging steps
Increase production capacity
Maximize resources utilization
Reduce/Eliminate the need for
overtime
Implement standardized work
Establish schedule flexibility
Track and sustain production
system
Observations Variability derives from other production
lines that are sharing resourcesChangeover time is not accounted for in
schedulingPlanned vs. Actual cycle times are not
consistentLabor intensive tasks on Mixer yields high
variability in cycle timesUnplanned production adjustments affect
scheduled availability of shared resources
Customer needs & Eng. Requirements
Engineering Metrics
Score Engineering Requirement Measure of PerformanceIdeal Value
Marginal Value
27 Food safety risks Rate of occurences 0 018 Ergonomic impacts Ergonomic Study, Before/After 0 036 Quality impacts Rate of occurences 0 072 Throughput Production efficiency percentage 100% +/- 0% 90% +/- 10%
57Characterization of all process steps
Variability and production efficiency percentage 100% 85%
21
Manufacturing Manager, Bakeshop Production Area Manager, Manufacturing Engineer, Line Team Leader and Production Line Workers agree with proposed solutions. Evaluation checklist All agree All agree
18 Implemented solution are consistent across crews and shifts. Binary (yes/no) Yes Yes
27 Tools that make system run smoothly. Current vs. Future productivity rate
20% inc mixer 10% inc divider
10% inc mixer 5% inc divider
39 Sustainable solution methods. Evaluation checklist All agree All agree
Proposed Solutions Improvement Task Priority Objective
Operations ManagementUpdate schedule with more accurate times
1
Make mixer its own resource and develop a single daily mixer schedule.Create changeover matrix for mixer and divider for use in scheduling.
Add Changeover time into schedule
Offset break schedules so another operator can run the mixer
Add in breaks of workers into schedule if breaks cannot be offset
A way to know if there is enough time to do more batches for the night
Have schedule of spiral 2 and commercial oven line up better
Mixer schedule located by the mixer
Mixing Prep Activities
Do justification analysis to have a part timer help open boxes when mixing choc chip cookies 2
To make a decision about whether a second operator is justifiable in the frozen cookie mixer process (for cookies with inclusions).
Mixing Clean Up Kaizen
Create system that allows the sanitation employee to be at the mixer at the required time to clean it 3
Create a system that allows the sanitation employee to be at the mixer at the right time.
Standard Work Implementation
Provide Work Instructions 4Create work instructions for revised process improvements
Scaling Process improvement
Modify cookies recipes format 5Increase usability of recipe by removing the need for calculations to find the number of bags/boxes needed.
Operations Management• Divider and mixer
changeover matrix was created to be added into the daily schedule.
• Sustainment: Update cycle times. Add new cookie types, as well as remove discontinued cookies. Update cycle times for each machine.
• Future Recommendations: Update the commercial dividing change over matrix. Create more detailed mixer change over matrix.
change die and Push out dough yield loss 22Change Machines to Vemag 40
Change of die required 20
Wash Down 60
Wash Down and change of die required 60
No change of die,or cleaning required 0Action Approx. required time (mins)
Cookie Pucks-
W/Nuts
Cookie Pucks-No
Nuts
Frz Choc Chip
CookyTO BE DISCD
ULT Choc Chip
SheetsNEW
Frz Ult ChChp Cooki 1.1oz
Frz Ult ChChp Nuts 1.1oz
Frz Chc Chc
Chunk Cky 1.1
Frz Oatmeal
Raisin 1.1oz
Frz Pnut Btr
Cookie 1.1oz
Frz 1.1 Coconut Macaroo
n
Frz Snickerd
oodle Pucks
Frz Meltaway Cookie
Frz Sugar Cut Out Circles
Frz Sugar sheet cut
out
Rectangle Breton
Dough
Square Breton Dough
Frz Tree Breton Dough
Rustic Fruit
Frz Gingerbread cut out sheets
Wg Oatmeal & Fruit Cookie
Wg Chocolate Hazel 'Nuttin Cookie
Cherry Almond
W/U W/U W/U U W/U W/U W/U W/U W/U W/U W/U W/U W/U VemagVemag +
Water Wheel
Vemag + Water Wheel
Vemag + Hand Press
Vemag Vemag Unifiller Unifiller Unifiller
Cookie Pucks-W/Nuts
W/U X 60 60 60 60 20 60 60 60 60 60 60 60 40 40 40 40 40 40 60 60 60Cookie Pucks-
No NutsW/U 0 X 22 22 22 22 22 60 60 60 60 60 60 40 40 40 40 40 40 60 22 60
Frz Choc Chip Cooky
TO BE DISCDW/U
22 22 X 22 22 22 22 60 60 60 60 60 60 40 40 40 40 40 40 60 60 60ULT Choc Chip
SheetsNEW
U22 22 22 X 20 20 60 60 60 60 60 60 60 40 40 40 40 40 40 60 22 60
Frz Ult ChChp Cooki 1.1oz
W/U 22 22 22 22 X 0 22 60 60 60 60 60 60 40 40 40 40 40 40 60 22 60Frz Ult ChChp
Nuts 1.1ozW/U 22 60 60 60 60 X 60 60 60 60 60 60 60 40 40 40 40 40 40 60 60 60
Frz Chc Chc Chunk Cky 1.1
W/U 22 22 22 22 20 20 X 60 60 60 60 60 60 40 40 40 40 40 40 60 60 60Frz Oatmeal Raisin 1.1oz
W/U 60 60 60 60 60 60 60 X 60 60 60 60 60 40 40 40 40 40 40 22 60 22Frz Pnut Btr
Cookie 1.1ozW/U 60 60 60 60 60 60 60 60 X 60 60 60 60 40 40 40 40 40 40 60 60 60
Frz 1.1 Coconut Macaroon
W/U 60 60 60 60 60 60 60 60 60 X 60 60 60 40 40 40 40 40 40 60 60 60Frz
Snickerdoodle Pucks
W/U22 22 22 22 22 22 22 22 22 22 X 22 22 40 40 40 40 40 40 22 22 22
Frz Meltaway Cookie
W/U 22 22 22 22 22 22 22 22 22 22 22 X 22 40 40 40 40 40 40 22 22 22Frz Sugar Cut Out Circles
W/U 22 22 22 22 22 22 22 22 22 22 22 22 X 40 40 40 40 40 40 22 22 22Frz Sugar sheet
cut outVemag 40 40 40 40 40 40 40 40 40 40 40 40 40 X 20 20 20 20 22 40 40 40
Rectangle Breton Dough
Vemag + Water Wheel 40 40 40 40 40 40 40 40 40 40 40 40 40 20 X 20 20 20 22 40 40 40
Square Breton Dough
Vemag + Water Wheel 40 40 40 40 40 40 40 40 40 40 40 40 40 20 20 X 20 20 22 40 40 40
Frz Tree Breton Dough
Vemag + Hand Press 40 40 40 40 40 40 40 40 40 40 40 40 40 20 20 20 X 20 22 40 40 40
Rustic Fruit Vemag 40 40 40 40 40 40 40 40 40 40 40 40 40 20 20 20 20 X 22 40 40 40
Frz Gingerbread cut out sheets
Vemag40 40 40 40 40 40 40 40 40 40 40 40 40 60 60 60 60 60 X 40 40 40
Wg Oatmeal & Fruit Cookie
Unifiller 60 60 60 60 60 60 60 60 60 60 60 60 60 40 40 40 40 40 40 X 60 22Wg Chocolate Hazel 'Nuttin
CookieUnifiller
60 60 60 60 60 60 60 60 60 60 60 60 60 40 40 40 40 40 40 60 X 60
Cherry Almond Unifiller 60 60 60 60 60 60 60 60 60 60 60 60 60 40 40 40 40 40 40 60 60 X
Product
Machine
From
To
Operations Management
• A mixing tracking sheet was developed for the operator to fill out to investigate the deviations that exist between scheduled and actual production at the mixer.
• A scheduling tool was created for the team leader to create a more accurate daily schedule.
• This schedule can be updated throughout the day as production plans change.
Operations Management
• Updated cycle times• Sanitation
• Breaks• Change over
C/T 1 2 3 4 5 6 7 8 9 10 11 120:00
0:10
0:20
0:30
0:40
0:50
1:00
Sub Shop Cookies (March 24-31)
Batch
Updated Engineering Requirements
C/T 1 2 3 4 5 6 7 8 9 10 110:00
0:10
0:20
0:30
0:40
0:50
1:00
Ultimate Cookies (March 28-29)
Batch
Updated Engineering Requirements
Sustainment:• Update cycle times as well
as change over times• Update sanitation times• Train all team leaders• Update scheduling tool
instructions
Future Recommendations:• Incorporate mixer
schedule into the ROSS system
• Separate changeover time and sanitation time
• Create similar tool for dividing schedule
• Integrate dividing times to create dividing schedule as well
Operations Management
Mixing Prep Activities• An experiment was
conducted to determine if an additional mixer operator would synchronize mixing and dividing steps.
• Only high volume cookies were analyzed.
• Adding an additional operator to the Sub Shop cookies and Sub Shop with Nuts cookies will have a production increase of 50% and 86%, respectively (based on cost analysis).
Standard Work Implementation • Standard work was
created for mixing top cookies for both one operator and two operators.
• This lists all best practices and average cycle times for each job element.
• This will help in training new mixing operators as well as improving current processes.
Updated Engineering Requirements
Sustainment:• Update rates • Update job element times• Update standard work
with best practices
Future Recommendations:• Test on other types of
cookies• Create standard work for
all cookies
Mixing Prep / Standard Work
Mixing Clean-Up Kaizen
Current Progress:
• Interviewed Jim Roode
about sanitation processes
• Agreed that sanitation can
work on a schedule
• Suggested ideal state would
be a one to two hour notice
• Sanitation employee will fill
out sanitation section of the
Mixer Operator Time Sheet
Future Recommendation:
• Map information flow
scenarios for mixer
sanitation
• Collect data on sanitation
cycle time
• Update schedule to
include sanitation
Scaling Process Improvement
• Each recipe was updated to include a full bags and partials column.
• Reduces possible errors in calculations and speeds up the process of pre-scaling
• Helps in training new operators
Future Recommendation:• Perform checks to ensure recipes are accurate.
Scaling Process Improvement
Buyer Checks Ingredient Size When Ordering
Material Receiver Performs Check as
Offloading Ingredient Box
Material Handler Performs Check as
Placing Box in Inventory
Material Handler Performs Check
when Picking Ingredient Box
Operator Performs Check when
Accepting Ingredient Box
Positive Outcomes
• Better understanding of the current state of the production
line.
• Provided tools that help with the decision making process on
the floor.
• Had weekly meetings with customer allowed everyone to
always be up to speed. Communication was the most
important element of project success.
• "Going to Gemba" was the best and most effective way to
obtain information.
• Had contingency plans for delays.
Project Improvement Areas
• Timing of the project can greatly impact analysis of
current state (i.e. seasonality).
• Align specific task with direct customer, this would
facilitate communication and proper implementation.
• Project scope should not be determined until the current
state of the system has been defined. Team needs to be
prepared for scope changes and scope creep with proper
contingencies.
Future Recommendations
• Sustainment is just as important as making process
changes and improvements.
• Wegmans should have a kick off meeting at start of project
(meet operators, line leaders)
• Organizational Chart for people involved in project
• Responsibility matrix for project tasks (who to direct
questions to)
• Better balance between defining process and implantation
Questions?