1. Wegmans Fresh Bread and Roll Scaling Area Phase Review I Erik Webster Kate Gleason Cecilia Enestrom Grant Garbach Andrew Tsai

2. Customer Needs Assessment Customer Need DescriptionComments/Status 1.0Layout Design for the New Scaling Area 1.1 Area for short-term storage 1.2 Area for long-term storage 1.3 Relocate the scaling area near the short-term storage area 1.4 AutoCAD drawing of the improved layout 2.0Sifting and screening dry ingredients 2.1 Determine the appropriate sifting and screening equipment 2.2 Improve product quality by reducing contaminants 2.3 Maintain or decrease the process time 2.4 Maintain or improve process ergonomics 3.0Lean Process Improvements 3.1 Reduce process time 3.2 Reduce shrink 3.3 Determine the future inventory management strategy 3.4 Create necessary SOP documents 4.0Ergonomics Improvements 4.1 Reduce the manual lifting of buckets 4.2 Reduce the manual lifting and manipulating of 50-lb bags

3. DMAIC Strategy Define 12/1/2008 – 12/19/2008 Measure 12/15/2008 – 1/16/2009 Analyze 1/16/2009 – 2/20/2009 Improve 2/20/2009 – 4/10/2009 Control 4/10/2009 – 5/15/2008 Project Timeline

4. Scaling takes place in 2 areas: Back Scaling Area Bin Area 50 lb bags are taken from the back scaling area while the remainder of what is needed is measured in the bin area.

5. Whatever is left over from the 50 lb bags is measured in the bin area by scooping out the ingredients from the bins, placing them in a barrel, and measuring it on the scale. There is currently 2 scales in the bin area.

6. Back Scaling Area Bags are removed off the skids manually onto batch carts.

7. The 50 lb bags, the liquid barrels, and the mixed dry ingredient barrels are put onto a cart and ready to be moved to mixing.

8. Opportunities for Improvement Back Scaling Area Bin Area Wegmans would like to move the bins to the back scaling area. This may involve the recommendation of getting rid of the bins altogether and implementing another system.

9. Opportunities for Improvement There are pounds of dry ingredient waste on the floor of the bin area. Possible causes: –Shape of scoop –Distance from bin to scale –Worker carelessness The daily # of repetitions

10. No standard long term, short term storage Not first in first out No clear labeling on where ingredients are located Scaling area location leads to unneeded walking (~ 31-39 steps) Existing Issues

11. Ingredient Weekly Pallets Used Round Up to Whole Pallets Peak Pallets Used Round Up to Whole Pallets Stoneground 10.00015.000 Specialty Stoneground 6.0008.000 Ultra Grain 4.0006.000 Vital Wheat Gluten 4.0005.000 Salt Superior 3.0004.000 Yeast 3.00004.0000 Breadmate 3.0004.000 DOH Conditn AA 2.0003.000 Watson Honey Bran Base 2.0000 Gran Sugar 2.0003.000 Watson Lite Wheat Base 2.0000 EZ Potato Base 2.000 Hearty Bread Base 2.0000 DM 1.0002.000 Watson Oat Bran Base 1.000 Stay Soft W 1.0002.000 White Rye Flour 1.00002.0000 NF 1.000 12 Grain Blend 1.000 Dry Dimalt/Non Diastatic 1.000 EZ Kaiser Base 1.0000.000 Non-Fat Dry Pro (Promix) 1.000 Ingredient Weekly Pallets Used Round Up to Whole Pallets Peak Pallets Used Round Up to Whole Pallets Buttermilk Blend 1.000 Watson Lite White Base 1.000 Canadian Oat Base 1.00002.0000 Med Granulated Sugar 1.0000 Potato Base (Vandenburgh) 1.0000.000 Brown Sugar 1.00002.0000 Course Cracked Wheat 1.0000 Corn Sugar Solids 1.000 Soy Flour 1.0000 Dry Molasses 1.0000 Odessa Pump Base 1.00000 Caravan Rye 12 Base 1.00000 Omega 3 Powder 1.0000 EZ Sour 1.0000 Whole Caraway Seeds 1.000 Ground Caraway 1.0000 Dry Molasses 1.0000.000 Cinnamon 1.0000 Seasoning (For seasoned stuffing bread) 0.00000 Dakota Specialty 0.000 Double Spice 0.000 B&V Flavor 0.000 Total 72.00089.000 Usage Rounded Up to Whole Pallet

12. Daily Ingredient Usage IngredientDaily Pallets Used (6 days) Daily Pallets Used in Peak times (6 days) Buttermilk Blend 0.0760.114 Watson Lite White Base 0.0750.112 Canadian Oat Base 0.0600.219 Med Granulated Sugar 0.0580.081 Potato Base (Vandenburgh) 0.0480.000 Brown Sugar 0.0370.169 Course Cracked Wheat 0.0370.052 Corn Sugar Solids 0.0360.051 Soy Flour 0.0310.042 Dry Molasses 0.0280.038 Odessa Pump Base 0.0280.046 Caravan Rye 12 Base 0.0170.034 Omega 3 Powder 0.0150.020 EZ Sour 0.0130.006 Whole Caraway Seeds 0.0100.014 Ground Caraway 0.0070.010 Dry Molasses 0.0020.000 Cinnamon 0.0020.141 Seasoning (For seasoned stuffing bread) 0.000 Dakota Specialty 0.000 Double Spice 0.000 B&V Flavor 0.000 Total 7.72611.329 IngredientDaily Pallets Used (6 days) Daily Pallets Used in Peak times (6 days) Stoneground 1.6472.341 Specialty Stoneground 0.8871.316 Ultra Grain 0.5870.881 Vital Wheat Gluten 0.5320.798 Salt Superior 0.4150.615 Yeast 0.4060.604 Breadmate 0.3480.519 DOH Conditn AA 0.2890.436 Watson Honey Bran Base 0.2550.298 Gran Sugar 0.2250.335 Watson Lite Wheat Base 0.2190.273 EZ Potato Base 0.2080.197 Hearty Bread Base 0.1910.310 DM 0.1470.223 Watson Oat Bran Base 0.1430.077 Stay Soft W 0.1340.204 White Rye Flour 0.0960.226 NF 0.0910.137 12 Grain Blend 0.0880.127 Dry Dimalt/Non Diastatic 0.0800.129 EZ Kaiser Base 0.0790.000 Non-Fat Dry Pro (Promix) 0.0790.133

13. Incoming Pallets Scaling Area Storage

14. Lack of Labeling What ingredient is it?

15. Improvements Create a long and short term storage Standardize amount of ingredients in storage areas Standardize location of ingredients in storage area Place scaling area in the short term storage area

16. Ergonomic Analysis Summarized Injury Data for 2008 4.6% of the reported injuries in 2008 in the Bake Shop can be attributed to the scaling operation. 9.6% of the total committed charges to the Bake Shop in 2008 can be attributed to the scaling operation. The committed charge is the amount charged to the Bake Shop by the Wegmans Risk Management Department. This is the amount that actually comes out of the Bake Shop’s worker compensation budget. 21.32 % of the incurred costs in 2008 from the Bake Shop can be attributed to the scaling operation. This is the amount of money in medical bills that the injury has cost Wegmans.

18. Equipment Specification and Preliminary Design Options Mobility of weighting station Floor layout, potential spacing for new equipments Screen size and testing Silo layout plan Potential sift and screen equipments

19. Mobility of weighting station Make: TORREY Model 1: EQM-200/400 W Model 2: EQM-W 400/800 The battery pack will last one shift. Operator need to plug it in to recharge.

20. Floor Layout and Potential Spacing No immediate spacing next to the 2 mixers No immediate spacing in the current scaling area Will determine equipment size based on ingredient usage

21. Screen Size and Testing Stone ground wheat will require screen size 10 or less Flour already utilize the silos and passes through screen size 30 Screen size 10 can be used for all other ingredients

22. New Silo Layout Obtain the new silo layout plan One of the two new silo will be used for stone ground wheat Currently it takes 8 operators approximately an hour to load the stone ground wheat into the mixer. The silo will help streamline the process as well as screen the ingredient.

23. 48” Round Sweco Separator 304 Stainless Steel Non-marking caster wheels Continuous Ground welds Fully washable $17,300

24. Separator Large enough for two bags Dump into scale bins Size 10 mesh –Easy change screens

25. Safer, Stronger, Cleaner Stable base Stronger construction No painted surfaces Minimal aggressive vibration

26. Dust collection system Reduce dust clouds Eliminates breathing small particles Reduced cleanup $6,500