commercial roll line shrink reduction p09712 levi stuck evan decotis cinthia sanchez joseph fitzery...
Post on 19-Dec-2015
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Commercial Roll Line Shrink Reduction
P09712
Levi Stuck Evan DeCotisCinthia SanchezJoseph FitzeryRyan Dennison
Customer NeedsCust.
Need #Importance Customer Need (Description) Comments / Status
Eliminate TIMWOOD Waste:Some aspects are beyond the scope of this
project. Focus will be on and Transportation and Defects.
CN1 3 a) Transportation WasteAbout 25 minutes on conveyor system. Improve
movement and flow of racks across facility.
CN2 1 b) Inventory Waste
Improvements may be realized by focusing on Transportation and Defects.
CN3 1 c) Motion Waste
CN4 1 d) Waiting
CN5 1 e) Overproduction
CN6 1 f) Overprocessing
CN7 9 g) Defects 5-10% current spoilage rate
Safety:
CN8 9 a) Maintain Current Standards Bakery currently meets standards but improving them is not a major focusCN9 3 b) Improving Current Standards
CN10 3 Implementing Flow Improvements Value stream mapping
CN11 9 Standardization of ProcessCurrently there is minimal standardization at the
plant
CN12 9 Introduce Metrics None existing, baseline needs to be established
CN13 3 Visual Aids Changeovers, hot pans, proof box time, etc.
CN14 9 Minimal Cost Do not exceed $5,000
Cust. Need #: Enables cross-referencing with Specifications
Importance: 9=Very Important, 3=Important, 1=Somewhat Important
Specifications
Eng. Spec. #
Importance Source Specification (Description)Unit of
MeasureMarginal
ValueIdeal Value
Comments / Status
ES1 9 CN7 Reduce the number of defects% reduction in
defects25% 75%
ES8 3 CN10, CN11
Throughput will be increased % rate increase 5% 15%
ES2 9 CN7 Categorize defects according to where each defect occurred # of areas >= 2 >= 5K-roll, Proof Box, Oven,
Conveyor, Bagging
ES3 9 CN7 Categorize defects by type # of defect types >= 2 >= 4Rolls not grouped, fingerprints in
dough, dry spots, etc.
ES5 1CN3, CN4,
CN10Reduction in unnecessary human labor
% labor time reduction
20% 75%
ES9 9 CN11 Process time variation will be reduced, standardization Minute range 30-45 10-20Alternative measurement:
standard deviations
ES4 3 CN8, CN9Ensure that design changes do not cause an increase in injuries and/or OSHA recordable incidents
% decrease in injuries
0% 20%
ES10 9 CN12Metrics for X% of all value-added operations (not including material handling)
% of VA operations
50% 100%
ES6 3 CN10Any changes to the line can be taught to someone with prior knowledge to the process within X minutes
Minutes 45 15Minimal time lost due to any
necessary retraining
ES12 3 CN12Data collection (metrics) can be taught to someone with no prior knowledge of process within X minutes
Minutes 45 10 Ability to capture metrics easily
ES11 1 CN12 All metrics can be collected within X minutes or less Minutes 30 min Real timeAllows for quick status reports
on line performance
ES13 3 CN13Intended message portrayed in 5 seconds or less, and provokes the proper response
Seconds <5 <1
ES14 3 CN14 This project will be implemented using little capital investment USD <= $5,000 <= $1,000
Eng. Spec. #: Enables cross-referencing to other documentsSource: Customer need #Importance: 9=Very Important, 3=Important, 1=Somewhat ImportantMarginal Value: Minimum value expectedIdeal Value: Best value possible within realistic expectations