1. Andreana Crance, Industrial & Systems Engineering Matt Syska, Industrial & Systems Engineering

2.  Project Name  Wegmans SD Projects 1 & 2  Project Number  P10711 & P10712  Project Family  R09170  Track  Modern Food Processing and Bakery Technology for Lean Production Systems  Start Term  2009-2  End Term  2009-3  Faculty Guide  Dr. John Kaemmerlen (ISE)  Technical Lead  Phil Bryan  Primary Customer  Wegmans Distrubution Center, Scott Young

3. Product Description /Project Overview The aim of this project is to improve a specific process in the Wegmans manufacturing facility., focusing on the Central Bakeshop or Culinary Innovation Center. The overall outcome of the project is to identify and implement process improvements in order to increase efficiency, and therefore throughput of the process. Key Business Goals/Project Deliverables The primary business goals of this process change is to:  Create standard work processes for different areas of facility  Standardize procedures (i.e. changeovers, storage)  Utilize workers’ time in a more efficient way  Improve overall efficiency of facility in order to make a greater profit  Improve safety conditions for all workers Primary Market /Project Opportunities Wegmans central bakeshop and culinary innovation center in Rochester, NY Secondary Market /Project Opportunities Similar Wegmans production facilities Stakeholders Wegmans Central Bakeshop and Culinary Innovation Center in Rochester, NY Scott Young and Wegmans’ engineering group Bakery and Culinary workers whom are effected by the changes Raw Material and Ingredients Providers Wegmans Distribution Center Community Community that purchases the products

4. Primary Customer(s) Wegmans Engineering Team  Scott Young: Provided many ideas for new projects for 2009 year. Provided insight into the projects.  Additional resources include: Mike Least (Manufacturing Engineer), Chris Isaacson, Jamie Rothfuss (Industrial Engineer)  In next 1-2 weeks: Contact Mike, Chris and Jamie to narrow down projects Other Stakeholder(s) Wegmans Bakery and Culinary Workers  Following facility tour and project selection: Must talk with bakery and culinary workers to get their input and feedback Past Senior Design Team(s) P09711 – Automation and Improvement of Packaging on the Cookie Line  Automating a perviously all hands-on process P09712 – Commericial Roll Line Shrink Reduction  Decrease amount of wasted rolls and improve effeciency of process P09713 – Bread and Roll Scaling Room  Make overall layout of room more efficient and effective for employees

5.  Wegmans operates a Central Bakeshop and Culinary Innovation Center in Rochester, NY.  2008-2009 AY first year for Wegmans projects.  DPM students in Fall 2008 defined 6 potential projects. Packaging Automation/Improvement for Cookie Line Fresh Bread and Roll Scaling Room Commercial Bread Line Shrink Reduction ERP ImplementationErgonomics Universal Rack System Packaging Automation/Improvement for Cookie Line Fresh Bread and Roll Scaling Room Commercial Bread Line Shrink Reduction ERP ImplementationErgonomics Universal Rack System

6.  P09711 – Cookie Line Automation  P09712 – Commercial Bread Line Shrink Reduction  P09713 – Fresh Bread and Roll Scaling Room

7.  Re-evaluated projects defined in Fall 2008 DPM with Wegmans: Packaging Automation/Improvement for Cookie Line Fresh Bread and Roll Scaling Room Commercial Bread Line Shrink Reduction ERP ImplementationErgonomics Universal Rack System Packaging Automation/Improvement for Cookie Line Fresh Bread and Roll Scaling Room Commercial Bread Line Shrink Reduction ERP ImplementationErgonomics Universal Rack System

8. Lean No Standardization High Volume, High Mix of products Batch Processing & Bulk Savings Loading Procedures Resource UsageScalable Safety Ergonmics Concerns Noise Issues Preventative Procedures Material Handling Transport of raw materials MixingTransferrableCustomizable Layout Design New Equiptment Storage Utilization Low cielingsCost effective Worker Relations More efficient set ups Manual process operation improvements Process Improvement Labor Effeciency Savings Ease of Use Environmentally friendly Sanitary Requirements Culinary Innovation Center more strict Easily cleaned Must meet health code

9. This Product or Process Needs to … Lean Processes Improve Loading Procedures Scalable solution Proper utulization of resoruces Safety Ensure safety of workers Stop problems before they occur Reduce current noise issues Material Handling Handle variety of materials Improve storage of large raw material Transferrable Layout Effeciently use old and new space Enable further expansion Cost effective changes

10. Improve Process’ at Wegmans Central Bakeshop and Culinary Innovation Center Lean Reduce time to load and unload machines Able to be sized up due to high demands Perform to the bottleneck Safety Perform to the set standards Be proactive in solving safety problems – report any issues Not bring noise levels above acceptable standard Material Handing Handle up to 2,000lbs of material Accessible and cost efficient storage Able to move facility to facility without failing Layout Improve flow of goods and people Effectivley use space in order to allow for expansion Be cost effective

11.  Ergonomics and Design of Tumbler Transport  Storage Utilization Standardization  Bakery Patisserie Efficiency  Noise Exposure Ergonomics Issue  Handling System for Meat Marinade  Bakery Bulk Bag Storage  Bakery Cheesecake Process Improvement  Batch Prep Room Simplification  Marinade Package Labeling Improvement  Tote (basket) Loading Process Improvement

12.  Wegmans staff very busy  Must be completed in 22 weeks  Wegmans does not have hard deadlines  Working with peoples’ workplaces

13. ActionDate Meet with faculty guide and tech lead to discuss possible projects Week 6/7 Set up facility tour with Wegmans Contacts Week 6/7 Analyze Projects Week 7/8 Discuss Top Project Choices with Wegmans Week 8/9