Wegmans Fresh Bread and Roll Scaling Area Project Review II Erik Webster Kate Gleason Cecilia Enestrom Grant Garbach Andrew Tsai

DMAIC Strategy Define 12/1/2008 – 12/19/2008 Measure 12/15/2008 – 1/16/2009 Analyze 1/16/2009 – 2/20/2009 Improve 2/20/2009 – 4/10/2009 Control 4/10/2009 – 5/15/2008 Project Timeline

Customer Needs Assessment Customer Need DescriptionComments/Status 1.0Layout Design for the New Scaling Area 1.1 Area for short-term storage 1.2 Area for long-term storage 1.3 Relocate the scaling area near the short-term storage area 1.4 AutoCAD drawing of the improved layout 2.0Sifting and screening dry ingredients 2.1 Determine the appropriate sifting and screening equipment 2.2 Improve product quality by reducing contaminants 2.3 Maintain or decrease the process time 2.4 Maintain or improve process ergonomics 3.0Lean Process Improvements 3.1 Reduce process time 3.2 Reduce shrink 3.3 Determine the future inventory management strategy 3.4 Create necessary SOP documents 4.0Ergonomics Improvements 4.1 Reduce the manual lifting of buckets 4.2 Reduce the manual lifting and manipulating of 50-lb bags

Engr. Spec. # Source: Customer Need Specification (description)Unit of Measure Marginal Value Ideal Value 1.0 Layout Specifications 1.1 Long-term storage areanumber of pallets Short-term storage areanumber of pallets Transport distance from short-term storage to the scaling areaft< , 1.2 Transport distance from short-term storage to long-term storageft Sifting and Screening Equipment Specifications Foreign Material Reportscount/year< Composed of non-contaminating materialyes/noyesYes Meets the necessary capacitybags/hour70 bags/hr95 bags/hr Change in process time due to sifting and screeningminutes Process Improvement Specifications 3.1 Shift time for scaling operatorhours<10< Material loss per cyclelbs. 4.0 Ergonomics Specifications , 4.2 Manual Liftinglifting index<3.0< , 4.2 Reported incidents% of count<4.6% , 4.2 Cost incurred due to work related injuries% of $$$<21.32%0

Ergonomics Background Information Lifting tasks pose a high risk of injury to the production employees 4.6% of injuries in the bakeshop can be attributed to the scaling operation Accounted for 9.6% of the total committed charges resulting from workplace injuries to the Bake Shop in 2008 Accounted for 21.32% of the total incurred costs resulting form workplace injuries to the Bake Shop in 2008 The scaling project aims to reduce these costs by eliminating or manipulating lifting tasks that are not ergonomically acceptable

Objective and Methodology Calculate the NIOSH Index for each lifting task The NIOSH Index provides a guideline to evaluate potential lifting-related injuries that could result from the scaling operation Index >2.00 poses an increased risk of injury to less capable workers Index >3.00 poses a risk of injury to all workers

Assumptions Asymmetry angle is zero The frequency of each task has no effect on the index The duration of each lifting task has no effect on the index The coupling for all lifts is “good”

Results

Ergonomic Specifications Ergo. Spec. # Lifting Task Specification DescriptionUnits Marginal Value Ideal Value 1.0Weight of bucket lifted from scale to shelving unit 1.1 Shelf 1lbs.<70 lbs.<51 lbs. 1.2 Shelf 2lbs.<50 lbs.<30 lbs. 1.3 Shelf 3lbs.<40 lbs.<20 lbs. 1.4 Shelf 4lbs.<40 lbs.<20 lbs. 2.0Weight of bucket lifted from scale to staging cartlbs.<70 lbs.<50 lbs. 3.0Origin height for bags lifted from pallets to staging cartin.2" to 42"12" to 16" 4.0Origin and destination height for bags lifted to equipment 4.1 Equipment (destination) heightin.36" 4.2 Origin heightIn.18" to 42"34" to 38"

Customer Needs Area for short-term storage Area for long-term storage Relocate the scaling area into the current short-term storage room AutoCAD drawing of improved layout New process flow diagram New Layout & Process Improvement

IngredientPeak Pallets Used5th Year5th Year Rounded Up Gran Sugar Vital Wheat Gluten Salt Superior DOH Conditn AA Breadmate DM Stay Soft W NF Buttermilk Blend Non-Fat Dry Pro (Promix) Dry Dimalt/Non Diastatic Specialty Stoneground Stoneground Yeast Omega 3 Powder Grain Blend Hearty Bread Base Canadian Oat Base Cinnamon White Rye Flour Dry Molasses IngredientPeak Pallets Used5th Year5th Year Rounded Up Ground Caraway EZ Sour Whole Caraway Seeds Watson Oat Bran Base EZ Potato Base Med Granulated Sugar Corn Sugar Solids Watson Lite White Base Soy Flour Watson Lite Wheat Base Watson Honey Bran Base Course Cracked Wheat Odessa Pump Base Caravan Rye 12 Base Seasoning (For seasoned stuffing bread) Ultra Grain Dakota Specialty EZ Kaiser Base Potato Base (Vandenburgh) Double Spice B&V Flavor Total : 114 pallets Bread and Roll Ingredients

IngredientPeak Pallets Used 5th Year Rounded Up Subtracting the pallet in short term storage Stoneground Specialty Stoneground Ultra Grain Vital Wheat Gluten Yeast Salt Superior Breadmate DOH Conditn AA Watson Lite Wheat Base Watson Honey Bran Base Hearty Bread Base Gran Sugar Watson Lite White Base Stay Soft W Non-Fat Dry Pro (Promix) NF EZ Kaiser Base Dry Dimalt/Non Diastatic DM Whole Caraway Seeds White Rye Flour Watson Oat Bran Base IngredientPeak Pallets Used 5th Year Rounded Up Subtracting the pallet in short term storage Soy Flour Seasoning (For seasoned stuffing bread) Potato Base (Vandenburgh) Omega 3 Powder Odessa Pump Base Med Granulated Sugar Ground Caraway EZ Sour EZ Potato Base Dry Molasses Double Spice Dakota Specialty Course Cracked Wheat Corn Sugar Solids Cinnamon Caravan Rye 12 Base Canadian Oat Base Buttermilk Blend Brown Sugar B&V Flavor Grain Blend Bread and Roll Ingredients Total : 69 pallets

Long Term Storage Pallets per Rack: 2 deep, 2 high (3rd row not used for ingredients) = 4 pallets 69 pallets needed 69 / 4 = = 18 racks needed

Proposed Long Term Storage Location

Distance: approx ft

Forklift Distance Forklift Truck Speed: 5 mph (440 feet per minute) Distance to Long Term Storage: inches ( feet) Calculation: / 440 = minutes ( ~51.5 seconds)

Short Term Storage Area Considerations –New Inventory Management Strategy How much of each ingredient in short term storage How ingredients will be stored How they will be transported from long to short term storage How often they will be transported from long to short term storage

Short Term Storage Area Conclusions: –Ingredients stay stored as pallets Keep current racking system Can transport easily with forklifts without any double handling of bags in long term storage area –Minimum storage requirement of 45 pallets in short term storage area Enough to stock at least 1 pallet of every ingredient and 3 of Stoneground

Short Term Storage Area Layout Implications: –Pallets per rack: 2 per row, 2 rows (not using third one) = 4 pallets –45 pallets needed –45 / 4 = 11.2 = 12 racks needed

Assigned Storage Locations

IngredientLocations Stoneground 5A,5B, 6B Specialty Stoneground 6A Ultra Grain 7A Vital Wheat Gluten 8A Yeast 4A Salt Superior 3A Breadmate 2A DOH Conditn AA 1A Watson Lite Wheat Base 20A Watson Honey Bran Base 19A Hearty Bread Base 18A Gran Sugar 17A Watson Lite White Base 16A Stay Soft W 15A Non-Fat Dry Pro (Promix) 21A NF 22A EZ Kaiser Base 23A Dry Dimalt/Non Diastatic 24A DM 25A Whole Caraway Seeds 26A White Rye Flour 14A IngredientLocations Watson Oat Bran Base 13A Soy Flour 12A Potato Base (Vandenburgh) 11A Omega 3 Powder 1B Odessa Pump Base 2B Med Granulated Sugar 3B Ground Caraway 4B EZ Sour 7B EZ Potato Base 8B Dry Molasses 20B Double Spice 19B Seasoning (For seasoned stuffing bread) 18B Dakota Specialty 17B Course Cracked Wheat 16B Corn Sugar Solids 15B Cinnamon 21B Caravan Rye 12 Base 22B Canadian Oat Base 23B Buttermilk Blend 24B Brown Sugar 25B B&V Flavor 26B 12 Grain Blend 14B Short Term Ingredient Pallet Locations

Restocking Schedule Results –Restocking schedule was created for the first 10 weeks using daily percentage of individual ingredient storage used AvgMaxMin Leveled # Pallets to Move Original # Pallets to Move # TripsRestocking Time (min) Minimum Maximum

Process Improvement Results –Restocking will take between 30 and 45 minutes every day –The maximum # of extra pallets due to leveling is 10, so the short term storage must have the capacity to store 55 pallets Will be stored on third shelf of racks –Moving bin area into short term storage eliminated the need for moving shelves No more ergonomic concern there

Current Scaling Area: approx. 320” x 126”

Current Process New Process

Process Improvement Major implications: –Restocking must be done before scaling starts at 2pm –No dead time between end of preparation and receiving batch cards –At least 35 minutes of walking time will be eliminated

Layout Design & Process Improvement Summary –Long term storage needs 18 racks –Short term storage area meets capacity requirements with bin area relocated into it –30 to 45 minutes of restocking with a forklift every day before 2pm –Eliminates: The worker’s walking and handling time by at least 45 minutes The need for the worker to lift heavy bins to and from high shelves

Layout Design & Process Improvement Next Steps –Fitting the equipment into the short term storage area –Determining where the equipment fits into the process –Interfaces between purchasing, forklift operator, and the scaling workers

Customer Needs for Sifting and Screening Dry Ingredients I.Determine the appropriate sifting and screening equipment. II.Improve product quality by reducing contaminants. III.Maintain or decrease the process time. IV.Maintain or improve process ergonomics.

Specifications From Customer A.The equipment will use the 460 volts power source available at the Wegmans facility. This type of generic power source is the easiest to install in manufacturing facilities. B.The equipment will fit within a three-pallet size area to minimize the footprint to allow more room for short-term ingredient storage. C.The equipment will be mobile. This will allow the machine to be more adaptable for changing conditions. D.The equipment will meet OSHA standard for noise level under 85dB. E.The equipment should be washable and possible use of compressed air at 90 to 100 psi. F.The equipment will be able to handle the throughput of dry ingredients including the 5% annual growth rate for the next four years. G.The equipment will not have parts that will contaminate the product. H.Can be safely operated by workers without special protection. I.All parts are stainless steel food grade compatible. J.Screen size to be mesh 10. K.NEMA 4X approved electrical box

Benchmarking Equipments for Alternate Equipment Selections Option 1: Company: Kemutec Powder Technologies Inc. Address: 130 Wharton Road, Bristol PA Telephone: (215) Model Number: K300C

Benchmarking Equipments for Alternate Equipment Selections Option 2: Company: Rotex Address: 1230 Knowlton Street Cincinnati, OH Telephone: (513) Model Number: M2120

Benchmarking Equipments for Alternate Equipment Selections Option 3: Company: Minox Elcan Address: 325 Waverly Avenue Mamaroneck, NY Phone: (914) Fax: (914) Model Number: SXE Round

Customer Needs I: Selected Equipment Company: SWECO Sales Rep: Jonathan P. Ansley Direct: (585) Office: (585) Fax: (585) Model Number: MX48S88

Customer Needs II: Improve Product Quality 8 incidents in the Foreign Material Report were the direct results of pieces of the ingredient bags found in the customer products. 1 incidents in the same report was the result of chipped wood from the pallet found in the customer product. The sifting and screening equipment will reduce foreign materials found in the customer products.

Equations Used

Calculations

Testing at Wegmans

Recommendation Sweco 48” Vibro-Energy Separator –Model MX48S88 Mesh 4 Screen Size –Capable of 8100lbs per hour –Assume density 45lbs/ft 3