Wegmans Frozen Cookie Capacity Increase

Final Project PresentationRichard Latham, Bridget Eggers, Tyler Brent, Valeria Gonzalez

A DAY IN THE PROCESSFrozen Cookies

Commercial Cookies

Problem Definition Current state High variability in and around

the production line

There is a bottleneck at mixing

Underutilization of resources

Staffing issues

Need for overtime

Lack of standardization

Production delays

Target state Establish synchronized flow

between scaling, mixing, dividing, and packaging steps

Increase production capacity

Maximize resources utilization

Reduce/Eliminate the need for overtime

Implement standardized work

Establish schedule flexibility

Track and sustain production system

Observations Variability derives from other production

lines that are sharing resourcesChangeover time is not accounted for in

schedulingPlanned vs. Actual cycle times are not

consistentLabor intensive tasks on Mixer yields high

variability in cycle timesUnplanned production adjustments affect

scheduled availability of shared resources

Customer needs & Eng. Requirements

Engineering Metrics

Score Engineering Requirement Measure of PerformanceIdeal Value

Marginal Value

27 Food safety risks Rate of occurences 0 018 Ergonomic impacts Ergonomic Study, Before/After 0 036 Quality impacts Rate of occurences 0 072 Throughput Production efficiency percentage 100% +/- 0% 90% +/- 10%

57Characterization of all process steps

Variability and production efficiency percentage 100% 85%

21

Manufacturing Manager, Bakeshop Production Area Manager, Manufacturing Engineer, Line Team Leader and Production Line Workers agree with proposed solutions. Evaluation checklist All agree All agree

18 Implemented solution are consistent across crews and shifts. Binary (yes/no) Yes Yes

27 Tools that make system run smoothly. Current vs. Future productivity rate

20% inc mixer 10% inc divider

10% inc mixer 5% inc divider

39 Sustainable solution methods. Evaluation checklist All agree All agree

Proposed Solutions Improvement Task Priority Objective

Operations ManagementUpdate schedule with more accurate times

1

Make mixer its own resource and develop a single daily mixer schedule.Create changeover matrix for mixer and divider for use in scheduling.

Add Changeover time into schedule

Offset break schedules so another operator can run the mixer

Add in breaks of workers into schedule if breaks cannot be offset

A way to know if there is enough time to do more batches for the night

Have schedule of spiral 2 and commercial oven line up better

Mixer schedule located by the mixer

Mixing Prep Activities

Do justification analysis to have a part timer help open boxes when mixing choc chip cookies 2

To make a decision about whether a second operator is justifiable in the frozen cookie mixer process (for cookies with inclusions).

Mixing Clean Up Kaizen

Create system that allows the sanitation employee to be at the mixer at the required time to clean it 3

Create a system that allows the sanitation employee to be at the mixer at the right time.

Standard Work Implementation

Provide Work Instructions 4Create work instructions for revised process improvements

Scaling Process improvement

Modify cookies recipes format 5Increase usability of recipe by removing the need for calculations to find the number of bags/boxes needed.

Operations Management• Divider and mixer

changeover matrix was created to be added into the daily schedule.

• Future Recommendations: Update the commercial dividing change over matrix. Create more detailed mixer change over matrix.

change die and Push out dough yield loss 22Change Machines to Vemag 40

Change of die required 20Wash Down 60

Wash Down and change of die required 60

No change of die,or cleaning required 0Action Approx. required time (mins)

Cookie Pucks-

W/Nuts

Cookie Pucks-No

Nuts

Frz Choc Chip

CookyTO BE DISCD

ULT Choc Chip

SheetsNEW

Frz Ult ChChp Cooki 1.1oz

Frz Ult ChChp Nuts 1.1oz

Frz Chc Chc

Chunk Cky 1.1

Frz Oatmeal

Raisin 1.1oz

Frz Pnut Btr

Cookie 1.1oz

Frz 1.1 Coconut Macaroo

n

Frz Snickerd

oodle Pucks

Frz Meltaway Cookie

Frz Sugar Cut Out Circles

Frz Sugar sheet cut

out

Rectangle Breton

Dough

Square Breton Dough

Frz Tree Breton Dough

Rustic Fruit

Frz Gingerbread cut out sheets

Wg Oatmeal & Fruit Cookie

Wg Chocolate Hazel 'Nuttin Cookie

Cherry Almond

W/U W/U W/U U W/U W/U W/U W/U W/U W/U W/U W/U W/U VemagVemag +

Water Wheel

Vemag + Water Wheel

Vemag + Hand Press

Vemag Vemag Unifiller Unifiller Unifiller

Cookie Pucks-W/Nuts

W/U X 60 60 60 60 20 60 60 60 60 60 60 60 40 40 40 40 40 40 60 60 60Cookie Pucks-

No NutsW/U 0 X 22 22 22 22 22 60 60 60 60 60 60 40 40 40 40 40 40 60 22 60

Frz Choc Chip Cooky

TO BE DISCDW/U

22 22 X 22 22 22 22 60 60 60 60 60 60 40 40 40 40 40 40 60 60 60ULT Choc Chip

SheetsNEW

U22 22 22 X 20 20 60 60 60 60 60 60 60 40 40 40 40 40 40 60 22 60

Frz Ult ChChp Cooki 1.1oz

W/U 22 22 22 22 X 0 22 60 60 60 60 60 60 40 40 40 40 40 40 60 22 60Frz Ult ChChp

Nuts 1.1ozW/U 22 60 60 60 60 X 60 60 60 60 60 60 60 40 40 40 40 40 40 60 60 60

Frz Chc Chc Chunk Cky 1.1

W/U 22 22 22 22 20 20 X 60 60 60 60 60 60 40 40 40 40 40 40 60 60 60Frz Oatmeal Raisin 1.1oz

W/U 60 60 60 60 60 60 60 X 60 60 60 60 60 40 40 40 40 40 40 22 60 22Frz Pnut Btr

Cookie 1.1ozW/U 60 60 60 60 60 60 60 60 X 60 60 60 60 40 40 40 40 40 40 60 60 60

Frz 1.1 Coconut Macaroon

W/U 60 60 60 60 60 60 60 60 60 X 60 60 60 40 40 40 40 40 40 60 60 60Frz

Snickerdoodle Pucks

W/U22 22 22 22 22 22 22 22 22 22 X 22 22 40 40 40 40 40 40 22 22 22

Frz Meltaway Cookie

W/U 22 22 22 22 22 22 22 22 22 22 22 X 22 40 40 40 40 40 40 22 22 22Frz Sugar Cut Out Circles

W/U 22 22 22 22 22 22 22 22 22 22 22 22 X 40 40 40 40 40 40 22 22 22Frz Sugar sheet

cut outVemag 40 40 40 40 40 40 40 40 40 40 40 40 40 X 20 20 20 20 22 40 40 40

Rectangle Breton Dough

Vemag + Water Wheel 40 40 40 40 40 40 40 40 40 40 40 40 40 20 X 20 20 20 22 40 40 40

Square Breton Dough

Vemag + Water Wheel 40 40 40 40 40 40 40 40 40 40 40 40 40 20 20 X 20 20 22 40 40 40

Frz Tree Breton Dough

Vemag + Hand Press 40 40 40 40 40 40 40 40 40 40 40 40 40 20 20 20 X 20 22 40 40 40

Rustic Fruit Vemag 40 40 40 40 40 40 40 40 40 40 40 40 40 20 20 20 20 X 22 40 40 40

Frz Gingerbread cut out sheets

Vemag40 40 40 40 40 40 40 40 40 40 40 40 40 60 60 60 60 60 X 40 40 40

Wg Oatmeal & Fruit Cookie

Unifiller 60 60 60 60 60 60 60 60 60 60 60 60 60 40 40 40 40 40 40 X 60 22Wg Chocolate Hazel 'Nuttin

CookieUnifiller

60 60 60 60 60 60 60 60 60 60 60 60 60 40 40 40 40 40 40 60 X 60Cherry Almond Unifiller 60 60 60 60 60 60 60 60 60 60 60 60 60 40 40 40 40 40 40 60 60 X

Product

Machine

From

To

Operations Management

• A mixing tracking sheet was developed for the operator to fill out to investigate the deviations that exist between scheduled and actual production at the mixer.

• A scheduling tool was created for the team leader to create a more accurate daily schedule.

• This schedule can be updated throughout the day as production plans change.

• Updated cycle times• Sanitation

• Breaks• Change over

Operations Management

C/T 1 2 3 4 5 6 7 8 9 10 11 120:00

0:10

0:20

0:30

0:40

0:50

1:00

Sub Shop Cookies (March 24-31)

Batch

Updated Engineering Requirements

C/T 1 2 3 4 5 6 7 8 9 10 110:00

0:10

0:20

0:30

0:40

0:50

1:00

Ultimate Cookies (March 28-29)

Batch

Updated Engineering Requirements

Sustainment:• Update cycle times as well

as change over times• Update sanitation times• Train all team leaders• Update scheduling tool

instructions

Future Recommendations:• Incorporate mixer

schedule into the ROSS system

• Separate changeover time and sanitation time

• Create similar tool for dividing schedule

• Integrate dividing times to create dividing schedule as well

Operations Management

Mixing Prep Activities•  An experiment was

conducted to determine if an additional mixer operator would synchronize mixing and dividing steps.

• Only high volume cookies were analyzed.

• Adding an additional operator to the Sub Shop cookies and Sub Shop with Nuts cookies will have a production increase of 50% and 86%, respectively (based on cost analysis).

Standard Work Implementation • Standard work was

created for mixing top cookies for both one operator and two operators.

• This lists all best practices and average cycle times for each job element.

• This will help in training new mixing operators as well as improving current processes.

Updated Engineering Requirements

Sustainment:• Update rates • Update job element times• Update standard work

with best practices

Future Recommendations:• Test on other types of

cookies• Create standard work for

all cookies

Mixing Prep / Standard Work

Mixing Clean-Up Kaizen

Current Progress:

• Interviewed Jim Roode about sanitation processes

• Agreed that sanitation can work on a schedule

• Suggested ideal state would be a one to two hour notice

• Sanitation employee will fill out sanitation section of the Mixer Operator Time Sheet

Future Recommendation:

• Map information flow scenarios for mixer sanitation

• Collect data on sanitation cycle time

• Update schedule to include sanitation

Scaling Process Improvement

• Each recipe was updated to include a full bags and partials column.

• Reduces possible errors in calculations and speeds up the process of pre-scaling

• Helps in training new operators

Scaling Process Improvement Future Recommendation:• Perform checks to ensure recipes are accurate.

Buyer Checks Ingredient Size When Ordering

Material Receiver Performs Check as

Offloading Ingredient Box

Material Handler Performs Check as

Placing Box in Inventory

Material Handler Performs Check

when Picking Ingredient Box

Operator Performs Check when

Accepting Ingredient Box

Positive Outcomes • Better understanding of the current state of the production

line.

• Provided tools that help with the decision making process on the floor.

• Had weekly meetings with customer allowed everyone to always be up to speed. Communication was the most important element of project success.

• "Going to Gemba" was the best and most effective way to obtain information.

• Had contingency plans for delays.

Project Improvement Areas• Timing of the project can greatly impact analysis of

current state (i.e. seasonality).

• Align specific task with direct customer, this would facilitate communication and proper implementation.

• Project scope should not be determined until the current state of the system has been defined. Team needs to be prepared for scope changes and scope creep with proper contingencies.

Future Recommendations• Sustainment is just as important as making process

changes and improvements.

• Wegmans should have a kick off meeting at start of project (meet operators, line leaders)

• Organizational Chart for people involved in project

• Responsibility matrix for project tasks (who to direct questions to)

• Better balance between defining process and implantation

Questions?