Xcellence Program1

Project Charter

Project Name:

Sponsor Opportunity Statement:

Team Leader:Project Type:Accounting:

Customers:

Benefits:

Barriers or Special Requirements:

Target End Date:

Jana Sherrill

6/18/2012

Jerrys Azondekon

White/Wheat Deli Sub Processing Improvement

Green Belt

Resources

Champion:

Subject Matter Experts:

Mike Least

Project Start Date:

Kathy Endres

Analysis shows that sub shop bread is currently being processed well below it's potential throughput rate and below the standard yield. This results in higher cost to produce, longer runs to produce, and the "rest" time in the holding freezer not being to spec.

Barriers or Special Requirements

Dennis McGovern

Customers & Benefits

production variability, changeover requirements, processing requirements, staffing limitations, skill set limitations

Core Team Members:

Consumers, Stores, Operations, Scheduling

Maximized production time on a critical resource, maximizing production using straight labor hours, achieving 100% service level for stores, achieving desired freezer time for sub shop bread (14 day dwell time)

4/2/2012

Project Description

Paul Fiorica

Bryan AllenJamie Rothfuss

Sponsor(s):

DEFINEDEFINE

Xcellence Program2

Project Charter

Defined Opportunity Statement:

In Scope:

Out of Scope:

Improvement Indicators

Baseline Goal Entitlement UnitsBusiness

MetricsHours Labor $

Ing Cost per Shippable

Unit

Throughput (WDS) 102 164 164 ca/hr Year 1 Result

Throughput (DS) 111 164 218 ca/hr Year 2 Result

Availability Hours Year 3 Result

Std Yield (WDS) 93.5 99.47 99.67 %

Std Yield (DS)94.19 99.67 99.67 %

Project Approval Dates (by Committee)

Define 4/7/2012 Measure 4/21/2012 Improve ControlAnalyze

Problem Statement

Estimated Business ResultsKey Indicators

There is an opportunity identified to supply customers with high quality products that meet their demand. The goal is to increase productivity on the Deli Sub lines through design and implementation of better process flows. This will reduce production cost and improve customer satisfaction.

Project Scope

Frz white deli sub and Frz wheat deli sub - setup, throughput, reliability, quality/yield, capability, c/o

All other product varieties on spiral 1

DEFINEDEFINE

Xcellence Program3

Project Timeline

31-Mar 14-Apr 28-Apr 12-May 26-May 9-Jun

DEFINE

MEASURE

ANALYZE

IMPROVE

CONTROL

Completed Work

Remaining Work

DEFINEDEFINE

Xcellence Program4

Tools Used

Tools Used in Project D M A I C Tools Used in Project D M A I CProcess Mapping Kaizen

SIPOC X Design of Experiements (DOE)

Voice of Customer (VOC) Line / Cell Design

Affinity Diagram Spaghetti Diagram

Brainstorming X X Pareto Analysis

Data Collection Plan X 5-Why & 3-Legged/5-Why

Rolled Throughput Yield Fishbone X

Value Stream Map (VSM) X Theory of Constraints

Swim Lanes Force Field Analysis

Statistical Thinking Set-up Reduction

Standard Work X Total Preventative Maintenance (TPM)

5s / Visual Control Poka-Yoke (Mistake Proofing)

Cause & Effect Pull Systems

FMEA Paired Comparisons

SPC / Control Charts Pilot

Measurement System Analysis Change Management

Capability Analysis X Control Plans

Multi-Vari Analysis Histograms

(other tools) (other tools)

(other tools) (other tools)

DEFINEDEFINE

Xcellence Program5

Process MapDEFINEDEFINE

Frozen Warehouse

Production Control

2

Packaging

1

Dividing & Rounding

Ingredients Warehouse

1

Mixing

CT= 14.5 / 19.5 mn

CO= 0.0 / 2.75 mn

Daily

Ingredients Suppliers

Purchasing

45 Days Order

Bi-Weekly

4 Weeks Forecast

Revised Daily Schedule

CT 11.5 / 17.0 mn

%Scrap = 0.02/0.00

% Remix =1.60/0.95

U/T =1200 mn

Shifts = 2

13.5/17.0 mn

60 mn

11.5/17.0 mn 3 50 mn 0.58 mn78.58 mn

60 mn

Stagging

Shipping

CT = 3 mn

%Scrap= 0.81 / 2.25

% Remix = 5.58/ 6.28

U/T =1200 mn

Shifts = 2

CT = 50 mn

%Scrap = 0.00/0.00

% Remix =0.00/0.00

U/T = 1200 mn

Shifts = 2

CT= 0.58/0.58 mn

%Scrap = 0.83/2.09

% Remix =1.17/0.00

U/T = 1200 mn

Shifts = 2

Save small stops by

standard work

Save loss in speed by standard work

Improve manual operations and

box maker availability

Detail schedule of share resources

plans

Deli Subs Project VSMWegmans -Bakeshop

Reduce Remix and Scrap Rate

Freezing

1

Proofing & Forming

Store Store

Daily

Xcellence Program6

Deli SubsProduction

UNCONTROLLABLE PARAMETERS

• Breakdowns• Stores Orders• Machine Type • Floor Layout

OUTPUTS• Packed Frozen

Wheat Deli Sub• Packed Frozen

White Deli Subs

Ingredients Warehouse

Wegmans Frozen

Warehouses

Suppliers Inputs Process Outputs Customer

DEFECTS• Forming Quality• Product

Consistency

Primary Distributors

Shipping

Secondary Distributors

INPUTS• Ingredients List• Bakery Ingredients• Mixer Settings• Divider Settings• Freezer Settings• Packaging

Materials• Labeling Settings

PROCESS CONTROLS• Ingredients Batching and

Mixing• Machine Settings• Machine Staffing• Daily Schedule execution

SIPOCDEFINEDEFINE

Wegmans Stores

Xcellence Program7

Fishbone DiagramMEASUREMEASURE

Low Throughput

Man

Machine

Method

Material

Staffing

Number of operators

Training Motivation

Lack of Standards

Breakdowns

Lacking Preventive maintenance

Environmental conditions

Lack of Visual Controls

Ingredients Shortage

Inaccurate Prescale/Batching

Foreign objects included

Lack of Expectations

Lack of shared resources plan

Xcellence Program8

Data CollectionMEASUREMEASURE

• Existing Mezzanine Tracking Sheet (Packing Operation Start and End Time, Case Count)

• Existing Mixing Schedule (Unload Time

• New Form for Remix, Scrap & Breakdown

• Time Study of Mixing and Packing Processes

• QA Test Results

• Artisan Process Control Recommendations

Xcellence Program9

Results OverviewANALYZEANALYZE

Wheat DS White DS0

10

20

30

40

50

60

70

80

90

100

Final Output

Final Output

Remix & Scrap

Remix & ScrapMixing Pace

Mixing Pace

Unused Machine

Capacity & Other Causes

Other Causes

Deli Sub Production Efficiency Chart

Other

Mixing Time

Remix and Scrap

Output Rate

Products

Rat

e (c

ou

nt/

mn

)

Xcellence Program10

Improvement AxisANALYZEANALYZE

• Schedule & Pace• Operation

Optimization• Batch Size

Mixing

• Machine Settings & Fine Tuning

• Operators Training• Machine Condition & Performance

Process Quality

Standard Work

Process qualityMixing

Xcellence Program11

Mixing AxisANALYZEANALYZE

• Simulate Process• Evaluate

Ergonomically• Improve Process

Xcellence Program12

Remix and Scrap AxisANALYZEANALYZE

• Process Quality Parameters• Recommended Settings• Possible adjustments

Xcellence Program13

Slide TitleIMPROVEIMPROVE

Coming Up Next !

Thanks for your Attention

Xcellence Program14

Slide TitleCONTROLCONTROL

(Add Control Tools and Update Slide Title)

Takeaway: What are the takeaways?Takeaway: What are the takeaways?

Xcellence Program15

Slide TitleCONTROLCONTROL

(Add Control Tools and Update Slide Title)

Takeaway: What are the takeaways?Takeaway: What are the takeaways?

Xcellence Program16

Potential Future Project ListCONTROLCONTROL

Potential Project Project DescriptionComplexity of Project

Payback of Project

Xcellence Program17

Takeaway: What are the takeaways?Takeaway: What are the takeaways?

Tips and Hints

• Complete the page 1 of Project Charter for new projects• Finish page 2 by the end of the Define phase

• Tell a “Story” with the presentation – walking the audience through your process with major takeaways at each step.

• Copy and paste the Takeaway kicker box at the bottom of this page to highlight items for slides

• Insert new slides, as necessary, for each phase• Keep the Gantt Chart and Tools Used slides up to date• Compress pictures used in presentation to minimize file size• List Potential Future Projects as they are discussed in project work