Project Status Update P10711 & P10712
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PROJECT STATUS UPDATEP10711 & P10712
Andreana Crance, Industrial & Systems EngineeringMatt Syska, Industrial & Systems Engineering
PROJECT STATUS UPDATE Project Name
Wegmans SD Projects 1 & 2 Project Number
P10711 & P10712 Project Family
R09170 Track
Modern Food Processing and Bakery Technology for Lean Production Systems Start Term
2009-2 End Term
2009-3 Faculty Guide
Dr. John Kaemmerlen (ISE) Technical Lead
Phil Bryan Primary Customer
Wegmans Distrubution Center, Scott Young
PHASE 0: PLANNING: MISSION STATEMENT
Product Description /Project OverviewThe aim of this project is to improve a specific process in the Wegmans manufacturing facility., focusing on the Central Bakeshop or Culinary Innovation Center. The overall outcome of the project is to identify and implement process improvements in order to increase efficiency, and therefore throughput of the process.
Key Business Goals/Project Deliverables The primary business goals of this process change is to:Create standard work processes for different areas of facilityStandardize procedures (i.e. changeovers, storage)Utilize workers’ time in a more efficient wayImprove overall efficiency of facility in order to make a greater profitImprove safety conditions for all workers
Primary Market /Project OpportunitiesWegmans central bakeshop and culinary innovation center in Rochester, NY
Secondary Market /Project OpportunitiesSimilar Wegmans production facilities
Stakeholders Wegmans Central Bakeshop and Culinary Innovation Center in Rochester, NYScott Young and Wegmans’ engineering groupBakery and Culinary workers whom are effected by the changesRaw Material and Ingredients ProvidersWegmans Distribution Center CommunityCommunity that purchases the products
PHASE 1: CONCEPT DEVELOPMENTIDENTIFY CUSTOMER NEEDS - INTERVIEWSPrimary Customer(s)
Wegmans Engineering TeamScott Young: Provided many ideas for new projects for 2009 year. Provided insight into the projects.
Additional resources include: Mike Least (Manufacturing Engineer), Chris Isaacson, Jamie Rothfuss (Industrial Engineer)
In next 1-2 weeks: Contact Mike, Chris and Jamie to narrow down projects
Other Stakeholder(s)Wegmans Bakery and Culinary Workers
Following facility tour and project selection: Must talk with bakery and culinary workers to get their input and feedback
Past Senior Design Team(s)P09711 – Automation and Improvement of Packaging on the Cookie LineAutomating a perviously all hands-on processP09712 – Commericial Roll Line Shrink ReductionDecrease amount of wasted rolls and improve effeciency of processP09713 – Bread and Roll Scaling RoomMake overall layout of room more efficient and effective for employees
PROJECT CONTEXT Wegmans operates a Central Bakeshop and
Culinary Innovation Center in Rochester, NY. 2008-2009 AY first year for Wegmans projects. DPM students in Fall 2008 defined 6 potential
projects.Packaging Automation/Impro
vement for Cookie Line
Fresh Bread and Roll
Scaling Room
Commercial Bread Line
Shrink Reduction
ERP Implementati
on
Packaging Automation/Impro
vement for Cookie Line
Fresh Bread and Roll
Scaling Room
Commercial Bread Line
Shrink Reduction
ERP
Implementation
CURRENT WORK P09711 – Cookie Line Automation
P09712 – Commercial Bread Line Shrink Reduction
P09713 – Fresh Bread and Roll Scaling Room
FUTURE WORK BASED ON CURRENT WORK
Re-evaluated projects defined in Fall 2008 DPM with Wegmans:
Packaging Automation/Impro
vement for Cookie Line
Fresh Bread and Roll
Scaling Room
Commercial Bread Line
Shrink Reduction
ERP Implementati
on
Ergonomics
Universal Rack System
Packaging Automation/Impro
vement for Cookie Line
Fresh Bread and Roll
Scaling Room
Commercial Bread Line
Shrink Reduction
ERP
Implementation
Ergonomics
Universal Rack System
AFFINITY DIAGRAM –RAW DATA FROM CUSTOMERS AND STAKEHOLDERS
LeanNo Standardization
High Volume, High Mix of products
Batch Processing & Bulk Savings
Loading ProceduresResource Usage
Scalable
OBJECTIVE TREE – WHY DOES THE CUSTOMER NEED THIS PRODUCT?
This Product or ProcessNeeds to …
Lean ProcessesImprove Loading
Procedures
Scalable solution
Proper utulization of
resoruces
SafetyEnsure safety
of workers
Stop problems before they
occur
Reduce current noise issues
Material HandlingHandle variety
of materials
Improve storage of large
raw material
Transferrable
LayoutEffeciently use old and new
space
Enable further expansion
Cost effective changes
FUNCTION TREE –WHAT DOES THIS PRODUCT NEED TO DO?
Improve Process’ at Wegmans Central Bakeshop and Culinary Innovation Center
LeanReduce time to load and unload
machines
Able to be sized up due to high
demands
Perform to the bottleneck
SafetyPerform to the set standards
Be proactive in solving safety
problems – report any issues
Not bring noise levels above acceptable
standard
Material HandingHandle up to 2,000lbs of
material
Accessible and cost efficient
storage
Able to move facility to facility without failing
LayoutImprove flow of
goods and people
Effectivley use space in order to
allow for expansion
Be cost effective
PRELIMINARY IDEAS Ergonomics and Design of Tumbler Transport Storage Utilization Standardization Bakery Patisserie Efficiency Noise Exposure Ergonomics Issue Handling System for Meat Marinade Bakery Bulk Bag Storage Bakery Cheesecake Process Improvement Batch Prep Room Simplification Marinade Package Labeling Improvement Tote (basket) Loading Process Improvement
PROJECT RISKS + RESTRAINTS Wegmans staff very busy Must be completed in 22 weeks Wegmans does not have hard
deadlines Working with peoples’ workplaces
FUTURE PLANWHERE DO YOU GO FROM HERE?
Action Date
Meet with faculty guide and tech lead to discuss possible projects
Week 6/7
Set up facility tour with Wegmans Contacts Week 6/7
Analyze Projects Week 7/8
Discuss Top Project Choices with Wegmans Week 8/9
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