Matthew Gundrum Zach Alsheimer Garth Sinclair Casey Bauman

Review of Problem DefinitionFunctional DecompositionMorphological ChartSystems ArchitecturePugh EvaluationTop 5 ConceptsRisk AssessmentFeasibility AnalysisGoing Forward

Current State Cheesecakes produced in the bakery are not easily removed from pans Employees warm cakes for apprx 1 min and slam pans onto table surface to finish removal process Desired State Minimal ergonomic concerns for employees Simplify the removal process / minimize pan damage Keep up with current production rate Constraints Avoid repeated heating and freezing of the cakes Solutions should not be capital intensive Food quality standards must be met while keeping appearance

9 Very Important 3 Important 1 Somewhat Important

 Pizza oven is set at 1 min  Time study for depanning After 10 samples we calculated an avg time of 8.3s for large cheesecakes  Larges seem easier due to weight  “Espresso chocolate crust breaks apart easier”  “Yogurt recipe showed more cracks in the crust”

*Adhesion Force applies to the crust sticking to the bottom of the cheesecake pan CHEESECAKE DEPANNING Overpower Adhesion Force* Slamming Pans on Table Minimize Adhesion Force* Heat in pizza oven to create internal lubricants Freezing Cycle Manipulation X->Y in A min Y->Z in B min - Find specific temps at variables Circumvent Adhesion Force* Manipulate Tray Design (Inserts/Springform)

OVERPOWER ADHESION FORCE Gravity Separate Edges Mechanical Assistance Mallet on Bottom of Pan MINIMIZE ADHESION FORCE More/Different lubricants Water bath Pan Textures Temperature Manipulation Freezing Cycle Pizza Oven Regular Oven CIRCUMVENT ADHESION FORCE Inserts Manipulate Tray Design Springform Pan Collapsible Sides

Material: Environment:

DatumOverpowerMinimizeCircumvent Dropping Slamming Separating Edges w/ Spatula Hammer on Bottom of Pan Mechanical Assistance for Flipping Gravity Put Upside Down Manipulate Freeze Cycle Time & Temp New or More Lubes Manipulate Cook Time & Temp Include Waterbath Process New Material or Texture for Pan Manipulate Reheat Time/Temp Insert for Bottom of Pan Springform or Collapsible Pan Criteria Ergonomic -++++SSSSS++ Production Rate -S++SSSSSSS+ Cost SS-SSSSS-S-- Testability S+++ Food Safety & Mat'l SSSS----SSSS Aesthetics --S-SSSSSSS+ Wet Bake SSSSSSSSSSS- Score **Green and Red highlighted boxes are considered categories that are noteworthy and should be looked at closer for either positive or negative results respectively

Flip Pans Upside Down: Find ideal time in process to flip pans and let sit until cakes fall freely Springform/ Collapsible Sides: Create product to make these pan designs wet bake- friendly Insert for Bottom of Pan: Placed on bottom of pan during baking process to let cakes fall easier Mallet to Bottom of Pan: Flip pans and tap gently with mallet in lieu of slamming on tables Mechanical Flipping Assistance: Potential for minor automation integrated into the process

IDRisk ItemEffectCause Likely- hood SeverityImportanceAction to Minimize RiskOwner 1 Proposed changes negatively impact quality Wegmans would fall short of internal quality requirements, and more prep time at store bakery Unexpected process improvement effects and lack of planning by MSD team 236 Complete necessary research/calculations and run small trials MSD Team 2 Proposed changes have no effects or possibly negative effects on process ergonomics Ergonomics would remain a concern for Wegmans cheesecake depanning line Proposed improvements lead to unexpected ergonomic concerns (repetitive motion, increased noise) 224 Meet with Nancy to discuss current ergonomic concerns and improvement ideas that Wegmans has not previously addressed Garth & Zach 3 Proposed process improvements conflict with union regulations Possible sanctions from union Lack of understanding about union regulations and restrictions by MSD team 133 During weekly meetings, discuss possible improvement solutions with Wegmans management to ensure no issues with unions MSD Team Wegmans 4 Changes made lead to decreased production time Smaller outputs lead to increase in necessary time running production line Process improvements involve either labor intensive tasks or greater waiting times for operators 236 Conduct time trials to set standards for current process as a benchmark Garth & Zach 5 Proposed improvements prove too capital intensive for Wegmans Wegmans would have to establish allowable budget for team Team cannot find a feasible 'no-cost' solution 122 Focus on 'no-cost' solutions, discuss possible alternatives with Wegmans if these are not effective MSD Team Wegmans

IDRisk ItemEffectCause Likely- hood SeverityImportanceAction to Minimize RiskOwner 6 Proposed changes lead to insufficient training of staff Lack of standard work and possible decrease in productivity and quality Proposed changes lead to higher degree of training, more tasks involved for certain operators 122 Once an improvement has been successfully identified, work with management to develop standard work for operators MSD Team Wegmans 7 Process improvements cannot be sustained over long term Return to the current process Insufficient fatigue testing133 Ensure design specs exceed the necessary conditions Casey & Matt 8Time constraint Unable to finish improvement project Procrastination of team, fall behind designed schedule 133 Meet weekly with Wegmans for updates, meet continuously as team and compare current status to schedule Casey 9 Satisfying each stakeholder Disconnect between management, workers, and MSD team What sounds good to management may make process more difficult for operators 224 Encourage all input and feedback from Wegmans perspective MSD Team 10 Communication issues with stake holders Difficulty obtaining necessary information, unclear project status Lost/Unsent s212 Have weekly meetings with customer to update on project progress and questions Zach 11 Team safety on Wegmans shop floor Team member is injured while on site Team not properly following Wegmans safety policies 133 Always be aware of surroundings while on the shop floor, comply with Wegmans safety regulations Casey & Garth

 Is a springform pan or collapsible pan possible with a wet bake?  Is our solution going to be accepted by the operators doing the work?  Will a pan insert affect the heat transfer that currently takes place in the tunnel oven?

MSD I Problem Definition (Weeks 1-3) Systems Design (Weeks 4-6) Subsystem Design (Weeks 7-10) Detailed Design (Weeks 10-13) Complete Design (Weeks 13-16) Gate Review (Week 17) MSD II (Spring Semester)

 Weeks 7 & 8: Observe process, perform further time studies, interview operators for opinions and ideas  Weeks 8 & 9: Test several of the low-cost and least disruptive concepts (Ex. Mallet to bottom of pan)  Week 10: Subsystems Design Review (Tuesday 10/28)

 What actually constitutes a Cheesecake with good atheistic quality?  We need grease specs (type & quantity)  Change to yogurt recipe – will ingredient changes affect our solutions?  Heating pattern in the tunnel oven