BRIDGET EGGERS, RICHARD LATHAM TYLER BRENT, VALERIA GONZALEZ Frozen Cookies Capacity Increase

Presentation Goals Is the current state of our project well defined? Is the information presented relevant to the project goal? Is there any missing information that you believe would be helpful? Feedback and questions are encouraged

Project Scope Establish synchronized flow between scaling, mixing, dividing and packaging steps in frozen cookie production for optimal productivity. Scaling Mixing Stage Dividing

Defining Current State  Undefined variability in and around the production line  There is a bottleneck between the mixing and dividing steps  Underutilization of resources  Scheduling issues  Use of overtime  Lack of standardization  Production delays

Frozen Cookie Demand 2013

Data Collection

Data Sources Frozen Bakery Tracking Form-  Actual Packaging Times (Cakes, Muffins, Doughnuts, Frozen Cookies) APV Commercial Oven Tracking Form  Actual Commercial Oven Times (Commercial Cookies) Frozen Bakery Tracking Form  Actual Dividing Times (Frozen Cookies) Weekly production schedules for commercial cookies  Scheduled Commercial Oven Times (Commercial Cookies) Weekly production schedules for frozen cookies  Scheduled Packaging Times (Cakes, Muffins, Doughnuts, Frozen Cookies) Frozen Cookie Cycle Times and Recipes Cookie Capacity & Capability

Seasonal Demand Data Cases

Number of Observations

Analysis

Actual vs. Scheduled Commercial Oven Production Time

Mixing

Mixing Station Time Cumulative TimeTask TimeTask 14:150:00:00 14:200:05:02 Setting up stationNVA 14:250:05:200:00:18Add ingredientVA 14:250:05:280:00:08Walk/Open/FoldNVA 14:250:05:380:00:10Add ingredientVA 14:250:05:420:00:04Walk/Open/FoldNVA 14:250:05:550:00:13Add ingredientVA 14:260:06:050:00:10Walk/Open/FoldNVA 14:260:06:400:00:35Add ingredientVA 14:270:07:510:01:11MixVA 14:310:11:520:05:12Grab more ingredientsNVA 14:330:13:140:01:22Add ingredientVA 14:340:14:050:00:51Walk/Open/FoldNVA 14:340:14:120:00:07Add ingredientVA 14:340:14:220:00:10Walk/Open/FoldNVA 14:340:14:290:00:07Add ingredientVA 14:340:14:540:00:25Walk/Open/FoldNVA 14:350:15:010:00:07Add ingredientVA 14:350:15:090:00:08Walk/Open/FoldNVA 14:350:15:210:00:12Add ingredientVA 14:390:19:200:04:11MixVA 14:390:19:450:04:24Grab more ingredientsNVA 14:400:19:580:00:13Add ingredientVA 14:400:20:040:00:06Walk/Open/FoldNVA 14:400:20:220:00:18Add ingredientVA 14:400:20:290:00:07Walk/Open/FoldNVA 14:400:20:470:00:18Add ingredientVA 14:400:20:520:00:05Walk/Open/FoldNVA 14:410:21:000:00:08Add ingredientVA 14:410:21:070:00:07Walk/Open/FoldNVA 14:410:21:190:00:12Add ingredientVA 14:420:22:400:01:21MixVA 14:440:24:530:02:13Dump doughNVA 14:470:27:070:02:14Move troughs, cover and label themNVA Percentage of VA vs. NVA per observation 12345Average VA NVA

Planned vs. Actual Mixing Time

Dividing

Dividing Station The following timeline shows value-added (colored sections) vs. non-value added (white sections) activities. Each color represents one trough There is not continuous flow within the station

Planned vs. Actual Dividing Time The following graph shows the scheduled vs. the actual time for frozen cookies on the divider

Actual vs. Scheduled Packaging Times

Conclusions Variability derives from other production lines that are sharing resources  Mixer with Commercial cookies  Blast Freezer with Cakes, Muffins & Doughnuts Changeover time is not accounted for in scheduling Planned vs Actual cycle times are not consistent Labor intensive tasks on Mixer yields high variability in cycle times Unplanned production adjustments affect scheduled availability of shared resources

Open items & future work Observation on the pre-scaling station Further analysis on commercial line change over times Further analysis on variability in the cake, muffin and doughnut lines Identify most effective and feasible solutions concepts

Q& A