frozen cookies capacity increase

BRIDGET EGGERS, RICHARD LATHAMTYLER BRENT, VALERIA GONZALEZ

Frozen Cookies Capacity Increase

Presentation Goals

Is the current state of our project well defined?

Is the information presented relevant to the project goal?

Is there any missing information that you believe would be helpful?

Feedback and questions are encouraged

Project Scope

Establish synchronized flow between scaling, mixing, dividing and packaging steps in frozen cookie production for optimal productivity.

Scaling

Mixing StageDividing

Defining Current State

Undefined variability in and around the production line There is a bottleneck between the mixing and dividing steps Underutilization of resources Scheduling issues Use of overtime Lack of standardization Production delays

Frozen Cookie Demand 2013

Dad's

Cookie

Pucks

no nu

ts

ult ch

chp n

o nuts

ult ch

chp n

uts

Cookie

Pucks

nuts

suga

r she

et

macar

oon

sable

oatm

eal r

aison

pean

ut bu

tter

snick

erdo

odle

chcc

hc ch

unk

0

5000

10000

15000

20000

25000

30000

Dad'sCookie Pucks no nutsult chchp no nutsult chchp nutsCookie Pucks nutssugar sheetmacaroonsableoatmeal raisonpeanut buttersnickerdoodlechcchc chunkOther

Data Collection

Data Sources

Frozen Bakery Tracking Form- Actual Packaging Times (Cakes, Muffins, Doughnuts, Frozen Cookies)

APV Commercial Oven Tracking Form Actual Commercial Oven Times (Commercial Cookies)

Frozen Bakery Tracking Form Actual Dividing Times (Frozen Cookies)

Weekly production schedules for commercial cookies Scheduled Commercial Oven Times (Commercial Cookies)

Weekly production schedules for frozen cookies Scheduled Packaging Times (Cakes, Muffins, Doughnuts, Frozen

Cookies)Frozen Cookie Cycle Times and RecipesCookie Capacity & Capability

Seasonal Demand Data

010002000300040005000600070008000

Frozen Cook-iesCakesMuffinsDonuts

Cas

es

Number of Observations

10 11 12 1 2 3 4 5 6 7 8 9 100

2

4

6

8

10

12

14

Process Observations

Time of day

Num

ber

of v

isit

s

Commercial MixingCommercial DividingFrozen Pre Scaling

Commercial MixingCommercial DividingFrozen Mixing

Frozen Dividing

Analysis

Actual vs. Scheduled Commercial Oven Production Time

Mixing

Mixing Station

TimeCumulative

Time Task Time Task 14:15 0:00:00 14:20 0:05:02 0:05:02 Setting up station NVA14:25 0:05:20 0:00:18 Add ingredient VA14:25 0:05:28 0:00:08 Walk/Open/Fold NVA14:25 0:05:38 0:00:10 Add ingredient VA14:25 0:05:42 0:00:04 Walk/Open/Fold NVA14:25 0:05:55 0:00:13 Add ingredient VA14:26 0:06:05 0:00:10 Walk/Open/Fold NVA14:26 0:06:40 0:00:35 Add ingredient VA14:27 0:07:51 0:01:11 Mix VA14:31 0:11:52 0:05:12 Grab more ingredients NVA14:33 0:13:14 0:01:22 Add ingredient VA14:34 0:14:05 0:00:51 Walk/Open/Fold NVA14:34 0:14:12 0:00:07 Add ingredient VA14:34 0:14:22 0:00:10 Walk/Open/Fold NVA14:34 0:14:29 0:00:07 Add ingredient VA14:34 0:14:54 0:00:25 Walk/Open/Fold NVA14:35 0:15:01 0:00:07 Add ingredient VA14:35 0:15:09 0:00:08 Walk/Open/Fold NVA14:35 0:15:21 0:00:12 Add ingredient VA14:39 0:19:20 0:04:11 Mix VA14:39 0:19:45 0:04:24 Grab more ingredients NVA14:40 0:19:58 0:00:13 Add ingredient VA14:40 0:20:04 0:00:06 Walk/Open/Fold NVA14:40 0:20:22 0:00:18 Add ingredient VA14:40 0:20:29 0:00:07 Walk/Open/Fold NVA14:40 0:20:47 0:00:18 Add ingredient VA14:40 0:20:52 0:00:05 Walk/Open/Fold NVA14:41 0:21:00 0:00:08 Add ingredient VA14:41 0:21:07 0:00:07 Walk/Open/Fold NVA14:41 0:21:19 0:00:12 Add ingredient VA14:42 0:22:40 0:01:21 Mix VA14:44 0:24:53 0:02:13 Dump dough NVA14:47 0:27:07 0:02:14 Move troughs, cover and label them NVA

Percentage of VA vs. NVA per observation1 2 3 4 5 Average

VA 0.4075 0.4130 0.5793 0.5843 0.5942 0.5157NVA 0.5925 0.5870 0.4207 0.4157 0.4220 0.4876

51%49%Value added time

Non-value added time

Planned vs. Actual Mixing Time

1 2 3 4 5 6 7 80:00:00

0:10:00

0:20:00

0:30:00

0:40:00

0:50:00

1:00:00

Sub Shop Cookies (Oct 1st and Oct 3rd)

Sub Cookie (Nut)Sub Cookie (No Nut)Scheduled Cycle Time

Batch

Tim

e (m

inut

es)

Planned vs. Actual Mixing Time

1 2 3 4 5 6 7 80:00:00

0:10:00

0:20:00

0:30:00

0:40:00

0:50:00

1:00:00

Ultimate Cookies (Oct 1st and Oct 3rd)

Ultimate w NutsUltimate (No Nut)Scheduled w NutsScheduled (No Nut)

Batch

Tim

e (m

inut

es)

Dividing

Dividing Station

The following timeline shows value-added (colored sections) vs. non-value added (white sections) activities.

Each color represents one troughThere is not continuous flow within the

station

Planned vs. Actual Dividing Time

The following graph shows the scheduled vs. the actual time for frozen cookies on the divider

Actual vs. Scheduled Packaging Times

Conclusions

Variability derives from other production lines that are sharing resources Mixer with Commercial cookies Blast Freezer with Cakes, Muffins & Doughnuts

Changeover time is not accounted for in scheduling

Planned vs Actual cycle times are not consistent

Labor intensive tasks on Mixer yields high variability in cycle times

Unplanned production adjustments affect scheduled availability of shared resources

Open items & future work

Observation on the pre-scaling stationFurther analysis on commercial line change

over timesFurther analysis on variability in the cake,

muffin and doughnut lines Identify most effective and feasible solutions

concepts

Q& A