Fresh Bread and Roll Scaling Room Erik Webster, Cecilia Enestrom, Kate Gleason, Grant Garbach, Andrew Tsai March 20 th, 2009

Agenda  Project Timeline  Business Objectives  Cost Implications New Layout and Process Ergonomic Analysis Sifting and Screening Machinery  Cost Summary  Improve and Control Plans

Project Timeline Six Sigma DMAIC Strategy  Start 12/01/2008 Define3 Weeks Measure5 Weeks Analyze6 Weeks Improve8 Weeks Control3 Weeks  End 5/15/2009

Business Objectives  Reduce labor costs Scaling worker’s shift is hrs  Target shift time is 8 hrs  Reduce costs due to injury during scaling processes Perform ergonomic analysis  Reduce hazardous heavy lifting  Reduce foreign material in dry ingredients Implement best practice  Implement sifting/screening equipment

Business Objectives  Reduce labor costs Scaling worker’s shift is hrs  Target shift time is 8 hrs  Reduce costs due to injury during scaling processes Perform ergonomic analysis  Reduce hazardous heavy lifting  Reduce foreign material in dry ingredients Implement best practice  Implement sifting/screening equipment

Current Layout and Process Scaling Worker Shift Starts at 12pm Ends at 10pm-12am

Projected Layout and Process Scaling Worker Shift Starts at 2pm Ends at 10 – 11pm

Cost Implications  Bin Area moved to Short Term Storage Area Less walking time  hr shift 8-9 hr shift Labor Savings of 20-40% for scaling worker

Business Objectives  Reduce labor costs Scaling worker’s shift is hrs  Target shift time is 8 hrs  Reduce costs due to injury during scaling processes Perform ergonomic analysis  Reduce hazardous heavy lifting  Reduce foreign material in dry ingredients Implement best practice  Implement sifting/screening equipment

Ergonomic Process Implications  21.32% of the incurred costs due to injuries within the facility for 2008 can be attributed to the scaling operation.  This translates to approximately $70,000  Our ergonomic analysis has identified which lifting tasks are hazardous. Lifting heavy buckets and ingredient bags over head Assuming many of these injuries can be attributed to hazardous heavy lifting tasks, the cost of injuries due to the scaling process will decrease as a result of our implemented standard work  Estimated 5-16% of the total incurred costs to the Bakery  Translates to approximately $17,500-$52,500

Business Objectives  Reduce labor costs Scaling worker’s shift is hrs  Target shift time is 8 hrs  Reduce costs due to injury during scaling processes Perform ergonomic analysis  Eliminate hazardous heavy lifting  Reduce foreign material in dry ingredients Implement best practice  Implement sifting/screening equipment

Sifting & Screening Equipment Company: SWECO Cost: $19,000

Cost Summary  Process Improvement Cost to move equipment and material 20-40% labor savings for scaling worker  Ergonomics Cost of training to alter procedures 5-16% savings in costs due to injury within the facility, $17,500-$52,500  Sifting & Screening Equipment Cost $19,000 Reduce foreign materials in the product

Improve and Control Plans  Shift time savings Layout of Bin Area Layout of Short Term Storage Area Design Short Term Storage Replenishment System  Implementation planning for the sifting and screening equipment Consider time and labor requirements

Questions?