DEFINING STEPS TO MSD II TYLER BRENT BRIDGET EGGERS VALERIA GONZALEZ RICHARD LATHAM

CONCEPTS TO KAIZENS  Started with concepts  Kaizen activities include our concepts  Prove feasibility and practicality of these concepts  Small, resource constrained, fast implementation  We welcome feedback

SCALING – A DAY IN THE PROCESS  Shares station w/ commercial.  Cross-training evident.  4 AM – Commercial Pre-Scaler comes in.  11 AM – Frozen Pre-Scaler comes in.  Multiple batches are pre-scaled at a time.  Ingredients are stored in multiple locations.  Work in process is not trackable.

SCALING KAIZEN  Add labels to pre-scaled ingredients  Speeds up communication  Less errors  Modify cookies recipes format  Less errors in scaling  Easier for training.  Checklist of whether ingredients are there before starting a batch  Prepared if low on ingredients  Can change plan earlier

ADD LABELS TO PRE-SCALED INGREDIENTS

REDUCE DEFECTS ON SCALING %INGREDIENTS SINGLE FULL BAGSPARTIALPROCEDURES STAGE Brown Sugar Cream together for 19.78Vream Rite Shortening seconds 0.61Salt Baking Soda STAGE Bessie Flour Add to above on high for 10.2Am. Beauty Cake Flour minutes STAGE Liquid Whole Eggs Add to above on high for 3 minutes 1.1Clear Vanilla Extract FB Soybean Oil(buckets) STAGE Chocolate Chips-1000 ct Add to above on mix thoroughly on high for 1 min 90 COOKIES PER CASE 100TOTAL: Cookie Pucks no Nuts

CHECKLIST OF WHETHER INGREDIENTS ARE THERE BEFORE STARTING A BATCH

MIXING – A DAY IN THE PROCESS  Shares with commercial.  Deviation between types.  Average cleaning time: 12 minutes  Labor driven process  Average process time and Actual vs. Scheduled:

MIXING KAIZEN  Have all boxes opened before being placed beside the mixer  Faster once on the mixer  Scale liquids (eggs, vanilla) ahead then store in pie room  Faster once on the mixer  Break down ingredient boxes after all mixing is complete  Reduces mixing cycle times  Tracking sheet for mixer  Tracking improvement for system

MIXING KAIZEN  Mixer schedule located by the mixer  Other lines know when mixer is available  Material handler knows when materials are needed at the mixer  After mixing, operator takes all unused ingredients away and checks schedule to see if any will be need for next product  Speeds up next product  Can be done by other employees  Assign roles to material handler to collect and return ingredients  Speeds up machine downtime  Relieves mixer operator of extra work  Have mixer operator do sanitation on mixer  Reduce downtime for mixing changeovers

MIXING KAIZEN  Get a 3 rd commercial trough  Less downtime on mixer  Have all ingredients put into one bucket so no box opening while on the mixer  Faster once on the mixer  Different boxes to receive ingredients in, easier to open  Faster to open and break down

DIVIDING – A DAY IN THE PROCESS  Shared with doughnuts, muffins, etc.  Average actual run time: 2 hrs and 33 mins  Start time: Min 5:49 pm Max 8:14 pm Avg 6:52 pm

AVERAGE DOWNTIME:

DIVIDING KAIZEN  Reassign roles for dividing staff  Reduces dividing downtime  Change type of wire  Will break less often  Ensure machine is setup on time  Maximize available time for dividing  One type of machine per day  Changeover time doesn’t interact with operation time

SYSTEM –A DAY IN THE PROCESS Frozen Cookies Commercial Cookies

SYSTEM-LEVEL KAIZEN (METHODS)  Update schedule with more accurate times  Schedule will reflect actual better.  Add changeover time into schedule  Schedule will reflect actual better.  Offset break schedules so another operator can run mixer  increased utilization of mixer  Add in breaks of workers into schedule if breaks cannot be offset  more accurate scheduling and planning of resources  Start commercial mixing earlier in the day  Frozen cookie mixing should have less late starts  Create standard work  best and fastest way, reduces variability

SYSTEM-LEVEL KAIZEN (METHODS)  Run commercial cookies with butter on a different day than frozen cookies with butter  more soft butter available, less nearby inventory  Mix sheet cookies the night before  more mixing time available  A way to know if there is enough time to do more batches for the night  get ahead for the next day, not run late  Have schedule of spiral 2 and commercial oven line up better  Scheduled Production = Actual Production, Reduce variability  Make communication board  Everyone knows what is going on.  Improve tracking board for management  Everyone knows what is going on.

SYSTEM-LEVEL KAIZEN (MAN)  Packaging workers come help with dividing  Dividing downtime reduced  Divider workers come help with mixing  Mixing downtime reduced  Add more cross training  Flexible staff to work different processes.

SYSTEM-LEVEL KAIZEN (MACHINE)  Fix frozen troughs and redesign to stop future problems  Safer and easier workflow