Fresh Bread and Roll Scaling Room MSD II Final Presentation Erik Webster, Cecilia Enestrom, Kate Gleason, Grant Garbach, Andrew Tsai May 15 th, 2009

Agenda  Project Deliverables from Week 3 Review of deliverables completed during MSD I  Layout Options Final Design Implementation Status  Replenishment Process Design Process Implementation Status  Air Quality Improvement Equipment Options Final Design

Project Deliverables from Week 3  AutoCAD drawings for the layout of the scaling area  Analysis of equipment needs for sifting and screening dry ingredients  Analysis of the current process ergonomics and necessary improvements  Standardized work practices that will reduce the process steps, time, cost, and/or labor requirements  Application of lean principles to reduce process waste  Detailed implementation plans that will allow for the realization of these improvements

Project Deliverables from Week 3  AutoCAD drawings for the layout of the scaling area  Analysis of equipment needs for sifting and screening dry ingredients  Analysis of the current process ergonomics and necessary improvements  Standardized work practices that will reduce the process steps, time, cost, and/or labor requirements  Application of lean principles to reduce process waste  Detailed implementation plans that will allow for the realization of these improvements

Sifting & Screening Equipment Update

 Determined products that could be sifted Only dry products Either Mesh 4/Mesh 10 or cannot be sifted  40% actual difference in throughput 40” vs 48” Save footprint size Limits target growth 40” cannot handle 2 of largest size bags  Allergen Issue Determined by Wegmans quality to not be an issue  Recommended washing of the equipment at regular intervals

Ergonomics Review  Recommendations were made to: Eliminate lifting scaling bins onto the third shelf of rolling carts. Avoid scaling workers lifting bags from the second rack shelf.

Project Deliverables from Week 3  AutoCAD drawings for the layout of the scaling area  Analysis of equipment needs for sifting and screening dry ingredients  Analysis of the current process ergonomics and necessary improvements  Standardized work practices that will reduce the process steps, time, cost, and/or labor requirements  Application of lean principles to reduce process waste  Detailed implementation plans that will allow for the realization of these improvements

New Layout  Option 1 Advantages  Enough space for bin area  Closer to staging area Disadvantages  Lose 30 pallet locations  Possible issues with congestion with fork lift  More motion for workers staging bags on carts

New Layout  Option 2 Advantages  Only lose 12 pallet locations  Possibility of using floor level of rack locations 9-14  Minimal congestion from fork lift  Less motion for workers staging bags on carts Disadvantages  Less space for bin area

New Layout Status  Progress Recommendation of what short term storage area was given  Bin area location  Ingredient pallet locations Bin area was moved into short term storage area  Continued Work Storage locations are still being finalized by Wegmans workers

Project Deliverables from Week 3  AutoCAD drawings for the layout of the scaling area  Analysis of equipment needs for sifting and screening dry ingredients  Analysis of the current process ergonomics and necessary improvements  Standardized work practices that will reduce the process steps, time, cost, and/or labor requirements  Application of lean principles to reduce process waste  Detailed implementation plans that will allow for the realization of these improvements

Project Deliverables from Week 3  AutoCAD drawings for the layout of the scaling area  Analysis of equipment needs for sifting and screening dry ingredients  Analysis of the current process ergonomics and necessary improvements  Standardized work practices that will reduce the process steps, time, cost, and/or labor requirements  Application of lean principles to reduce process waste  Detailed implementation plans that will allow for the realization of these improvements

Replenishment System  Necessary to ensure replenishment is finished prior to the arrival of daily batch cards so scaling is not postponed Should be a highly visual, easy to use system  Kanban system Cards and post

Replenishment System Design  How will the fork truck be able to replenish the short term storage before 2pm every day?

Replenishment System Design  How will the fork truck be able to replenish the short term storage before 2pm every day? Need to know average daily consumption of each ingredient in order for the fork truck driver to know which ingredient needs to be replenished each day.

Replenishment System Design  How will the fork truck be able to replenish the short term storage before 2pm every day? Need to know average daily consumption of each ingredient in order for the fork truck driver to know which ingredient needs to be replenished each day. How will we determine the average daily consumption levels?

Replenishment System Design  How will the fork truck be able to replenish the short term storage before 2pm every day? Need to know average daily consumption of each ingredient in order for the fork truck driver to know which ingredient needs to be replenished each day. How will we determine the average daily consumption levels?  Tabletop simulation  22 days of data

Replenishment System Design  How will it be communicated to the fork truck driver which ingredients to replenish each day?

Replenishment System Design  How will it be communicated to the fork truck driver which ingredients to replenish each day? Kanban cards

Replenishment System Design  How will it be communicated to the fork truck driver which ingredients to replenish each day? Kanban cards  Who will be responsible for collecting kanban cards each day?

Replenishment System Design  How will it be communicated to the fork truck driver which ingredients to replenish each day? Kanban cards  Who will be responsible for collecting kanban cards each day? Scaling workers via Kanban post Location of kanban post

Replenishment System Design  How will the scaling workers determine if the ingredient has hit its kanban level? Ingredient signs will display their kanban level

Replenishment System Design  How will the scaling workers determine if the ingredient has hit its kanban level? Ingredient signs will display their kanban level  Simple for low quantity kanban levels, but how do scaling workers quickly count replenish levels of >10?

Replenishment System Design  How will the scaling workers determine if the ingredient has hit its kanban level? Ingredient signs will display their kanban level  Simple for low quantity kanban levels, but how do scaling workers quickly count replenish levels of >10? Kanban line

Replenishment System Status  Progress Ingredient signs were made with kanban levels Kanban cards have been made  Continued Work Because storage locations are still being finalized,  Kanban cards must also be finalized  Kanban lines must be placed on appropriate racks  Floor tape needs to be laid around scaling area Need kanban post Staff training will be done this Wednesday

Project Deliverables from Week 3  AutoCAD drawings for the layout of the scaling area  Analysis of equipment needs for sifting and screening dry ingredients  Analysis of the current process ergonomics and necessary improvements  Standardized work practices that will reduce the process steps, time, cost, and/or labor requirements  Application of lean principles to reduce process waste  Detailed implementation plans that will allow for the realization of these improvements

Risks Assessment RiskProbabilitySeverityPreventative Actions Fork truck resources are not available for implementation19Detailed cutover plan with Wegmans Operators do not comply with storage locations91 Locations will be flexible to adjust to the changing needs of the system. Operator training. Capacity of room is not sufficient for new system with anticipated future growth 33 Several layout alternatives will be considered and simulation to verified capacity Manual resources not available for implementation19Detailed cutover plan with Wegmans Increase in ergonomic and safety risks39 Store ingredients to minimize dangerous lifting using simulation tool Fork truck work increases39 Simulation tool created to verify fork truck requirements. Research alternatives to fork trucks Staging area does not have sufficient capacity11 Detailed layout with input from floor supervisors and operators The shift time for the scaling operator does not decrease or increases19 Time estimated using process flow diagram and walking distances Leveling kanban system fails due to process variability33Simulation tool to verify kanban system validity Fork truck drivers and operators do not comply with kanban levels for the short-term storage area 99 Simulation tool to demonstrate validity of the system. Operator training and involvement. Needed supplies are not available at start of implementation39Detailed cutover plan with Wegman's

Air Handling System MSD II

Air Handling System  Customer Needs Assessment Improve Air quality Reduce Air Particulate size Help improve area cleanliness Will not interfere with sifting process Will not violate OSHA or Wegmans guidelines

Custom Designed Air Handling System

CAD Drawings

Selection Matrix for COTS

Shick Equipment

Recommendations  As a best practice, Wegmans should implement at least one sifting piece of equipment to reduce foreign material. Recommendation for equipment: Sweco vibratory sifter with Mesh 4  To improve bakery air quality, improve safety, and reduce health concerns, Wegmans should implement an air handling system equipped with dust collection Recommendation for equipment: Shick

Thank you to.. Scott YoungJohn Kaemmerlen Mike LeastPhil Bryan Chris Isaacson …And the rest of the staff from Wegmans, Aloi, Shick, and Sweco who made this project possible.