Download Week 3 Presentation

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
Wegmans.
the process following implementation by
Customer Needs Revisited
Customer Need
1.0
Description
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
1.0
Specification (description)
Unit of
Measure
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
2.2
2.1
Composed of non-contaminating material
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
count/time
yes/no
Process Improvement Specifications
3.1
3.1
Total process time per cycle
3.3
3.2
Material loss per cycle
4.0
minutes
lbs.
Ergonomics Specifications
4.1
4.1, 4.2
Manual Lifting
4.2
4.1, 4.2
Reported incidents
lifting index
count; $$
Marginal
Value
Ideal Value
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