Wegmans Frozen Cookie Capacity Increase Final Project Presentation
Wegmans Frozen Cookie Capacity Increase Final Project Presentation Richard 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 Target state Establish synchronized flow between scaling, mixing, dividing, and packaging steps Increase production capacity Maximize resources utilization Reduce/Eliminate the need for overtime Lack of standardization Implement standardized work Production delays Establish schedule flexibility Track and sustain production system Observations Variability derives from other production lines that are sharing resources Changeover time is not accounted for in scheduling Planned vs. Actual cycle times are not consistent Labor intensive tasks on Mixer yields high variability in cycle times Unplanned production adjustments affect scheduled availability of shared resources Customer needs & Eng. Requirements Engineering Metrics Score 27 18 36 72 57 21 18 27 39 Engineering Requirement Measure of Performance
Food safety risks Ergonomic impacts Quality impacts Throughput Rate of occurences Ergonomic Study, Before/After Rate of occurences Production efficiency percentage Variability and production efficiency Characterization of all process steps percentage Manufacturing Manager, Bakeshop Production Area Manager, Manufacturing Engineer, Line Team Leader and Production Line Workers agree with proposed solutions. Evaluation checklist Implemented solution are consistent across crews and shifts. Binary (yes/no) Tools that make system run smoothly. Sustainable solution methods. Current vs. Future productivity rate Evaluation checklist Ideal Value 0 0 0 100% +/- 0% Marginal Value 0 0 0 90% +/- 10% 100% 85% All agree All agree Yes Yes 20% inc mixer 10% inc 10% inc mixer divider 5% inc divider All agree All agree Proposed Solutions Improvement Task Priority Objective Operations Management Update schedule with more accurate times 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 1 Make mixer its own resource and develop a single daily mixer schedule. Create changeover matrix for mixer and divider for use in scheduling. 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. 4 Create work instructions for revised process improvements 5 Increase usability of recipe by removing the need for calculations to find the number of bags/boxes needed. Standard Work Implementation Provide Work Instructions Scaling Process improvement Modify cookies recipes format Operations Management To Cookie Cookie Pucks- Pucks-No W/Nuts Nuts Product From Machine Cookie PucksW/Nuts Cookie PucksNo Nuts Frz Choc Chip Cooky TO BE DISCD ULT Choc Chip Sheets NEW 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 Macaroon Frz Snickerdoodle Pucks Frz Meltaway Cookie Frz Sugar Cut Out Circles Frz Sugar sheet cut out Frz Ult ChChp Cooki 1.1oz Frz Ult ChChp Nuts 1.1oz Frz Chc Chc Chunk Cky 1.1 Frz Frz Pnut Frz 1.1 Frz Frz Frz Sugar Frz Sugar Rectangl Oatmeal Btr Coconut Snickerd Meltawa Cut Out sheet cut e Breton Raisin Cookie Macaroo oodle y Cookie Circles out Dough 1.1oz 1.1oz n Pucks Square Breton Dough Frz Tree Breton Dough Vemag + Vemag + Vemag + Water Water Hand Wheel Wheel Press W/U W/U
60 60 40 60 40 60 60 X W/U U W/U Vemag + Water Wheel Vemag + Square Breton Water Dough Wheel Vemag + Frz Tree Breton Hand Dough Press Rustic Fruit Vemag Rectangle Breton Dough Frz Gingerbread cut out sheets Wg Oatmeal & Fruit Cookie Wg Chocolate Hazel 'Nutti n Cookie Cherry Almond Frz Choc ULT Choc Chip Chip Cooky Sheets TO BE NEW DISCD Vemag Unifiller Unifiller Unifiller Action No change of die,or cleaning required Change of die required Wash Down Wash Down and change of die required change die and Push out dough yield loss
Change Machines to Vemag Approx. required time (mins) 0 20 60 60 22 40 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. 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 Updated Engineering Requirements Sub Shop Cookies (March 24-31) 1:00 0:50 0:40 0:30 0:20 0:10 0:00 C/T 1 2 3 4 5 6
Batch 7 8 9 10 11 12 Updated Engineering Requirements Ultimate Cookies (March 28-29) 1:00 0:50 0:40 0:30 0:20 0:10 0:00 C/T 1 2 3 4 5 Batch 6 7 8 9 10 11 Operations Management 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 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 Mixing Prep / Standard Work 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 Clean-Up Kaizen Current Progress: Future Recommendation: Interviewed Jim Roode about Map information flow scenarios 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 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 Scaling Process Improvement Future Recommendation:
Perform checks to ensure recipes are accurate. Buyer Checks Ingredient Size When Ordering Material Receiver Performs Check as Offl oading 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?
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