P10712CHEESECAKE PROCESS

IMPROVEMENT

Andreana Crance, Kevin Rodas, Rob Santora, Jeremy Smith, Matt Syska

Meeting Agenda

Brief Project Summary 5 min.Project Statement 5 min.System Overview 10 min.Customer Needs & Engineering Specifications 5 min.Risks & Contingencies 5 min.What we have done so far 20 min.Concept Selection 15 min.Target Specs – How we will measure success 10 min.Improvement Ideas 10 min.MSDI Plan of Action 5 min.

P10712 Cheesecake Process Improvement

The mission for the cheesecake process improvement is to increase the efficiency and effectiveness of cheesecake production in order

to meet customer demand in both quantity and quality of the cheesecakes.

Focusing on:

Worker Safety

Worker Productivity

Efficiency of Process

Proper utilization of equipment

Scrap Reduction

Project Approach

Due to the scattered processes taking place for the cheesecakes, we thought it would be best to break the project into larger categories:

Greasing Crumbing Pre-Tunnel Oven

Mixing, Pouring, Loading Oven Post-Tunnel Oven

Unloading oven, into freezer Slicing Packaging

System Overview

Value Stream Map

Customer Needs & Engineering Metrics

Customer Needs & Engineering Metrics

Customer Needs & Engineering Metrics

Customer Needs & Engineering Metrics

Risks and Contingencies

Risks and Contingencies

Risks and Contingencies

Process Evaluation

WeightGreasing Crumbing Pre-Tunnel

OvenPost Tunnel

Oven Slicing Packaging

Score Score Score Score Score Score

Efficiency 25% 1 3 9 1 9 9

Utilization 25% 1 3 9 3 9 3

Safety 25% 9 3 9 3 3 3

Equipment 10% 3 9 9 3 3 3

Scrap 15% 3 9 1 3 3 9

• Pre process clean up

• Sprayer Calibration

• Human bending

Greasing

Efficiency 1

Labor 1

Ergonomic 9

Equipment 3

Scrap 3

What we have observed in Greasing:

What we have observed in Crumbing:

No Direct Observation as of 10/2/2009

Known Issues: Uneven distribution of crumbs

Leads to scrap issues Manual process Nonconformity of crumb size Crumb displacement at batter drop (pre-oven

load)

Crumbing

Efficiency 3

Labor 3

Ergonomic 3

Equipment 9

Scrap 9

Pre-TunnelPre Oven

Efficiency 9

Labor 9

Ergonomic 9

Equipment 9

Scrap 1

• Cluttered area

• Human bending

• Labor intensive

Post-TunnelPost Oven

Efficiency 1

Labor 3

Ergonomic 3

Equipment 3

Scrap 3

• Cluttered area

• Manual process

• No standards

Slicing Issues 5S issues Labor Utilization Material Handling transitions Scrap Issues Machine maintenance reactive

TPM – Be proactive! Staffing setup Almost identical labels (marble vs. plain) Lack of Quality Check-One instance of packing defective cheesecake Walking 2s spin time for machine Ergonomics – Bending and reaching Putting covers on causes quality issues / lost productivity No monitoring of cheesecake time on floor (out of freezer) Variation in results due to lack of process control

Slicing

Efficiency 9

Labor 9

Ergonomic 3

Equipment 3

Scrap 3

Packaging

• No dedicated labor

•Reaching and bending

•Lack of organization

Packaging

Efficiency 9

Labor 3

Ergonomic 3

Equipment 3

Scrap 9

Overall Issues

No standard procedure No standard location for equipment on floor Improper/inadequate tools used Lack of set schedule for cheesecake process Variable batch sizes Lack of standard quality checks Unnecessary movement (time & ergonomics

concern) Current machines may not be ideal Lack of continuous flow

Concept Selection

Discussion

Target Specifications – Marginal and Target Values

Metric No. Metric Importance Units Marginal Value Target Value1 average labor

bottleneck utilization9 percentage per year >80% >85%

2 risk of injuries 9 (benchmarking unit using NIOSH, etc)

25% reduction of benchmarking unit

75% reduction of benchmarking unit

3 people travel distance 1 % travel distance reduction

10% 25%

4 cycle time / cheesecake (minus bake time)

3 min. 90% of current cycle time

75% of current cycle time

5 number of defective products

3 Percentage scrap 75% of current defect rate

50% of current defect rate

6 number employees on cheesecake process

3 employees One employee reassigned

More than one employee reassigned

7 throughput rate 3 throughput/hour 110% of current value 125% of current value8 process improvement

has full ROI for customer

9 Years 1 Year 0.5 Years

9 Solutions meet Wegmans specific

health code standards

9 Y/N Y Y

10 Cheesecake retains “homemade” feel

9 Y/N Y Y

11 Process changes can meet holiday demand

9 Y/N Y Y

List of Possible Ideas

Efficiency Standardize batch size Continuous flow of process Waste reduction maintenance for

equipment: Dropper, greaser, slicer Standard locations for materials and

equipment

List of Possible Ideas

Scrap Quality Checks: “Defect Board” Calibration of equipment: Dropper, greaser, etc.

Efficiency, Safety Reduce total travel distance: people and

materials

Efficiency, Safety, Equipment Eliminating unnecessary motions, providing

proper tools

List of Possible Ideas

Crumbing - (Labor Utilization, Scrap, Equipment) Automated or assisted “Crumber”

Pre/Post Tunnel Oven - (Scrap, Utilization) Regulate water for baking: volume controlled

and assisted

Packaging - (Scrap, Efficiency, Utilization) Alternative packaging methods

MSDI Plan – Our steps forward