Wegmans Freezer Inventory Control MSD #12714 Ben Whipple Emily Burns Tim Hogan Ben Jilson
Dec 14, 2015
Wegmans Freezer Inventory Control MSD #12714
Ben WhippleEmily BurnsTim HoganBen Jilson
Today’s Agenda
Current state Customer needs Spec list Scope
Proposed Solutions Selection matrix Proposed solution sets
Risk Assessment Next Steps
Current state
Customer needs listCustomerNeed #
Importance(1 high - 3 low) Description
CN1 1Non-held finished goods should make their way to FF2 in an efficient manner,
minimizing the time spent waiting in the freezer.
CN2 2 Reduce dripping incidents in the freezer.
CN3 1 Reduce impact of dripping in the freezer.
CN4 2 Way to ensure finished goods leaving the warehouse have been recorded.
CN5 2 Way to record product has entered the finished goods warehouse
CN6 2Simple way to differentiate between cases that hold varying types of product
when coming down spiral 1 and spiral 2.
CN7 1 Increase usable space in freezer
CN8 1 Decrease need for space
CN9 2 Freezer organization that takes into account day to day variations.
CN10 1 Ability to quickly locate skid within the freezer.
CN11 2 Ability to quickly locate WIP rack within the freezer
CN12 3 Take into account changes being made for RSC3.
CN13 2 Organized storage location for quality samples while they are in the freezer.
CN14 2 Allow quality holds to be easily accessed.
CN15 2 Defined owner to provide raw materials to production
CN16 2 Defined owner to receive raw materials
CN17 2 Ensure QA holds and limited production runs are removed in a timely manner.
CN18 3 Defined owner for storage and handling of WIP
Spec listCustomer Need Spec Numerical Goal
CN1 Number of finished goods pallets not on hold <5 at any time
CN2 Reduction in # of dripping incidents >50%
CN3 Reduction in Goods damaged by dripping >50%
CN4 # of pallets not recorded < 5 a week
CN5 # pallets not recorded < 5 a week
CN6 # of cases palletized incorrectly <2 a week (How to measure?)
CN7 # of accessible pallet position 10% increase at high volume levels
CN8 Average number of pallets in freezer (weekly running average) 40% reduction
CN9 System takes into account all possible levels of demand Yes
CN10 Time to find specific skid <30 seconds
CN11 Time to find specific WIP rack <30 seconds
CN12 Take into account changes being made concerning RSC3 Yes
CN13 Organized storage location for QA Samples Yes
CN14 # QA hold pallets not accessible 0
CN15 Defined Ownership of Raw Material removal Yes
CN16 Defined Owner for Receiving raw materials Yes
CN17 Defined owner for the storage and handling of WIP Yes
CN18 Defined Owner for Holds (QA and limited production) Yes
Proposed Scope
This project is to analyze the current operating state of the Wegman's Bakery Freezer, identify process shortfalls that are contributing to the "out of control" state identified by the customer, develop and apply solutions to those shortfalls deemed to be within the control of the client, implement these solutions in a timely and cost effective manner, and develop a plan for sustaining these solutions in a way that results in an "in control" process for the foreseeable future
Proposed Solutions
Raw Materials
Proposed solution set: Raw materials Recommendations
Designated transfer spots Optimize number of racks Optimize use of racking Standard put away rules Central information board
with raw material locations White boards
Considerations Color coding scheme Colored paths More frequent orders Pallet stacking Dedicated aisles Signage Magnet boards
WIP
Proposed solution set: WIP Recommendations
Prioritize locations White boards Standard put
away/pick process
Considerations Color coding scheme Colored paths Dedicated aisles Magnet boards
Finished Goods
Proposed solution set: Finished Goods Recommendations
Show obvious signal when a QA hold can be removed
Central information board Designated transfer spots Optimize number of racks Optimize use of racking Remove café support Standard put away rules White boards Magnet boards
Considerations Signage Color coding scheme Colored paths Remove commercial support Dedicated aisles Pallet stacking Analyze effects of reefer
availability Case differentiation methods
Different colored tape (group’s choice)
Marker Stickers Different colored boxes Worker training Better labels
Proposed solution set: QA Samples
Considerations Specialized racks New containers Signage Moving storage to QA
area
Recommendations Put QA samples in
space pallets cannot fit Standardize put away
rules
Risk Assessment
Next StepsDetailed Design Phase Week 6 Week 7 Week 8 Week 9 Week 10 Week 11
Develop pallet position layout plan
Develop put away process
Analyze use of flow racks, number and process
Create Detailed Plan for implementing Case Marking
Evaluate RM order policies, determine impact, suggest optimal order frequency
Design White Board/Magnet Board use policy
Evaluate Feasibility of customer container/racking for QA samples
Define and Document processes and declare owners
Create signage and marking conventions for the freezer
Develop freezer organization changeover plan
Develop retraining plan
Evaluate effect of reefer delays of varying amounts, quantify impact
Develop Evaluation Plan, data gathering and metrics generation
Create and Deliver Detailed Design Review