P09713 – Bread and Roll Scaling Room Sponsored by Wegmans R09710 - Modern Food Processing and Bakery Technology for Lean Production Systems Kate Gleason.
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P09713 – Bread and Roll Scaling Room
Sponsored by Wegmans
R09710 - Modern Food Processing and Bakery Technology for Lean Production
Systems
Kate Gleason Cecilia EnestromErik Webster
Roadmap Description and Overview
Mission Statement:The Modern Food Processing and Bakery Technology for
Lean Production Systems project roadmap lays out a series of projects for the Wegmans bakery facility that will improve major aspects of the company's processes. Each project may be used as a tool to educate RIT students in Lean process improvement techniques and can be iterated many times in the future to provide additional benefits to both Wegmans and the RIT Senior Design Program.
Roadmap Business Goals and Deliverables
Identify specific improvement projects within the facility
Develop production metrics to evaluate improvements based on the needs and goals of each production line
Implement improvement projects to reduce costs associated with wastes and inefficiencies within the facility
Properly document all improvements and process changes as these projects are implemented
Create process documentation where it is currently lacking
Project Stakeholders
Primary Customers: Wegmans Facility and Employees Scott Young, Manufacturing Engineering Manager Chris Isaacson, Industrial Engineer
Other Stakeholders: John Kaemmerlen, Faculty Advisor Mark Smith, RIT Senior Design
Project Improvement Process
TRACK Phase I Phase II Phase III Phase IV
Process Improvem
ent
Identify Flow and Current State
Waste Reduction
Set-up Time and
Changeover Reduction
Improve Layout Design
Safety
Improved Documentation
and Safety Analysis
Implement 5S:Sort, Set in
order, Shine, Standardize,
Sustain
Ergonomic Projects at High Risk
Areas
Ergonomic
Projects at Low Risk
Areas
Material Handling
Identify Material Handling Waste
Standardize Material
Handling Flow
Improve and Implement Material Handling
Procedures
Metrics
Track Current Metrics,
Implement Current Metric Documentation
Create a Tracking
System for Metrics
Visual Controls and
Documentation for Metrics and System Status (Real-
Time)
Improve Metrics
Equipment
Analyze Current Equipment and Maintenance
Procedure
Create and Implement
Documentation for Equipment
Update Out-of-Date (bottleneck) Equipment
P09713 Bread and Roll Scaling Room Layout and Process Improvement
Line Phase IPhase
IIPhase
IIIPhase
IV
Bread and Roll Scaling Room
Document current process flow and
work practices
Identify areas of process
and layout improveme
nt
Design and implement
the new layout
Design and implement
the new process
procedures
Bread and Roll Scaling Room Layout and Process Improvement
Project Name Bread and Roll Scaling Room Layout and Process ImprovementProject Number P09713RoadmapR09710- Modern Food Processing and Bakery Technology for Lean
Production SystemsStart Term 2008-2End Term 2008-3Faculty Guide Professor Kaemmerlen (Industrial and Systems Engineering Department) Primary Customer Wegmans Facility and EmployeesScott YoungChris Isaacson
Bread and Roll Scaling Room Layout and Process Improvement
Current State• All scaling and measuring of ingredients for the bread
and roll line is performed in the scaling room• Currently the ingredients are stored in 50-lb bags which
are removed from storage racks by hand, measured on the scale, and moved by cart to their respective areas
• Double handling of ingredients is occurring at the two scaling locations
• There is no process for sifting and screening the dry ingredients. This would help reduce debris mixed into the batter
• The layout is less than optimal, processes and work practices are not standardized, and ergonomics is a major concern
Bread and Roll Scaling Room Layout and Process Improvement
Mission StatementDocument all work practices and processes for
the bread and roll scaling operation to promote standardized work, develop a new process and layout for the scaling area that is conducive with Lean practices, and design solutions that will create a sifting and screening process that is ergonomically sound and promotes improved work flow.
Bread and Roll Scaling Room Layout and Process Improvement
Key Business Goals/Project DeliverablesDocument all current processes and work
practicesDevelop alternative processes for scaling the dry
ingredientsReduce/eliminate redundancies and double
handling in the processDevelop a process for sifting and screening the
dry ingredientsDevelop the layout for the new scaling areaIdentify other opportunities for improvement in
the scaling area
Bread and Roll Scaling Room Layout and Process Improvement
Assumptions and ConstraintsResources for designing solutions and equipment are
limited but available.Budget will be constrained based on decisions made
by WegmansWegmans’ engineering resources are limited but
availableSpace is limited in the area where the scaling process
will be located and existing materials in the area will be relocated or eliminated
The bread and roll line will be moving to a new location near the new scaling location in the future
Bread and Roll Scaling Room Layout and Process Improvement
Preliminary Customer NeedsRelocate and redesign the layout for the
scaling area near the bread and roll lineImprove the safety and ergonomics of the
processDevelop a process for sifting and screening dry
ingredientsEliminate double handling of dry ingredientsDocument and standardize process proceduresIdentify and implement Lean process
improvements
Preliminary Risk AssessmentCost/Budget
Insufficient funds to design and implement solutions for sifting and screening
Customer ApprovalWegmans does not approve of the solutions
developed by the project teamSpace Restrictions
The area reserved for the new scaling area will not support the process that is developed by the project team
Bread and Roll Scaling Room Layout and Process Improvement
Bread and Roll Scaling Room Layout and Process Improvement Staffing Requirements
Name Discipline
Role
John Kaemmerlen
Faculty Guide
Faculty Guide, will work closely with the team on an on-going basis to facilitate success of project.
Cecilia Enestrom
IE Will serve as Co-Project Manager and focus on the design of the new layout.
Kate Gleason
IE Will serve as Co-Project Manager and concentrate on developing the new scaling processes.
Erik Webster
IE Will serve as Co-Project Manager and concentrate on the design and ergonomics of the new sifting and screening process.
TBD ME Develop new equipment for sifting and screening process.
TBD ME Develop new equipment for new layout and scaling processes.
Bread and Roll Scaling Room Layout and Process Improvement Preliminary Work Breakdown Structure
Person Week 0-1 Tasks
Week 1-2 Tasks
Week 2-3 Tasks
Cecilia Enestrom – Co-Project Manager
Meet to discuss specific team assignments.
Review current layout and new area available in AutoCAD
Take necessary measurements in current and new area
Kate Gleason – Co-Project Manager
Meet to discuss specific team assignments.
Observe current processes and work flow
Document current processes and work flow
Erik Webster –Co-Project Manager
Meet to discuss specific team assignments.
Observe current procedures and qualitatively measure ergonomics
Quantitatively measure the ergonomics of current procedures
ME Read through project located on EDGE website.
Gain an understanding of the process
Measure parameters that are related to design solutions
ME Read through project located on EDGE website.
Gain an understanding of the process
Measure parameters that are related to design solutions
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