P09713 – FRESH BREAD AND ROLL SCALING ROOM

Week 3 Presentation

Senior Design I: Winter 2008-2009

Cecilia Enestrom, Kate Gleason, Erik Webster, Grant Garbach, Andrew Tsai

Project Timeline

Define: Week 1 – Week 3 Project Scope Team Roles Work Breakdown Structure Customer Needs Assessment

Measure: Week 3 – Week 5 Data Collection Plan Baseline Data Collection Project Specifications Data Organization

Project Timeline (continued)

Analyze: Week 5 – Week 10 Perform the data analysis necessary to fully

understand the process and make recommendations for improvement.

Improve: Senior Design II Prepare formal recommendations and

justifications for the necessary process improvements.

Control: Senior Design II Re-evaluate the process following

implementation by Wegmans.

Customer Needs Revisited

Customer Need Description

1.0 Layout Design for the New Scaling Area

1.1 Area for short-term storage

1.2 Area for long-term storage

1.3 Relocate the scaling area near the short-term storage area

1.4 AutoCAD drawing of the improved layout

2.0 Sifting and screening dry ingredients

2.1 Obtain the appropriate sifting and screening equipment

2.2 Improve product quality by reducing contaminants

2.3 Maintain or decrease the process time

2.4 Maintain or improve process ergonomics

3.0 Lean Process Improvements

3.1 Reduce process time

3.2 Reduce shrink

3.3 Determine the future inventory management strategy

3.4 Create necessary SOP documents

4.0 Ergonomics Improvements

4.1 Eliminate the need to manually lift buckets

4.2 Eliminate the need to manually lift and manipulate 50-lb bags

Specifications Revisited

Engr.Spec. #

Source:Customer

Need Specification (description)

Unit ofMeasure

MarginalValue

Ideal Value

1.0   Layout Specifications      

1.1 1.1 Volume of long-term storage area ft3    

1.2 1.2 Volume of short-term storage area ft3    

1.3 1.3 Transport distance from short-term storage to the scaling area ft    

1.3 1.1, 1.2 Transport distance from short-term storage to long-term storage ft    

2.0   Sifting and Screening Equipment Specifications      

2.1 2.2 Defective batches due to contaminants count/time    

2.2 2.1 Composed of non-contaminating material yes/no    

2.3 2.1 Meets the necessary capacity lbs/batch    

2.4 2.3 Change in process time due to sifting and screening minutes    

3.0   Process Improvement Specifications      

3.1 3.1 Total process time per cycle minutes    

3.3 3.2 Material loss per cycle lbs.    

4.0   Ergonomics Specifications      

4.1 4.1, 4.2 Manual Lifting lifting index    

4.2 4.1, 4.2 Reported incidents count; $$    

Ergonomics Data Collection

Major Issue: The constant manual lifting tasks required throughout the process is of concern to the customer

Perform the initial analysis using the NIOSH Lifting Equation

Data to collect: Weight and dimensions of the scaling buckets Lifting origins and destinations Worker posture Lifting frequency

Will determine if further analysis is necessary for any process tasks

Potentially use 3DSSP

Layout Data Collection

Major Issues: Inventory is unorganized and there are large transport distances between the storage area and scaling

Obtain existing AutoCAD drawings and verify accuracy

Determine the space constraints within the facility for both storage areas and production areas Square footage of long-term storage, short-term storage,

and production areas Storage rack capacity

Collect data to determine space requirements Volume of ingredients used per day, week, month Pallet dimensions Volume of ingredients per pallet Space required to support production process Current transport distances between storage and scaling

Process Data Collection

Major Issues: The current process takes too long, is unpredictable, and work is not standardized

Need to gain a firm understanding of the current process and procedures A list of dry ingredients and frequency of use A list of products with associated ingredients and

frequency of production Map process steps and flow Process cycle time Task times Operator utilization Shrink Examine current documents used for scaling

Equipment Requirements Data Collection Major Issue: Contaminants get into the mix

because there is no equipment to sift and screen the dry ingredients

Need to gain a firm understanding of what Wegmans needs and can support Current rate of product contamination Wegmans standards for equipment selection Capacity requirements Sanitation procedures and cleaning requirements Physical space constraints Manual vs. Automated Safety issues associated with equipment placement

Contact suppliers to investigate possible solutions