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

2. 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

3. 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.

4. 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

5. ADD LABELS TO PRE-SCALED INGREDIENTS

6. REDUCE DEFECTS ON SCALING %INGREDIENTS SINGLE FULL BAGSPARTIALPROCEDURES STAGE 1 21.76Brown Sugar8485379129Cream together for 19.78Vream Rite Shortening271498504020 seconds 0.61Salt2976372.20 0.61Baking Soda0722002.20 STAGE 2 13.78Bessie Flour0848545010Add to above on high for 10.2Am. Beauty Cake Flour520460370 2 minutes STAGE 3 5.09Liquid Whole Eggs07235218.50 Add to above on high for 3 minutes 1.1Clear Vanilla Extract042752404 0.28FB Soybean Oil(buckets)326108101 STAGE 4 32.79Chocolate Chips-1000 ct088755116.67416.67Add to above on mix thoroughly on high for 1 min 90 COOKIES PER CASE 100TOTAL: 360.57 Cookie Pucks no Nuts

7. CHECKLIST OF WHETHER INGREDIENTS ARE THERE BEFORE STARTING A BATCH

8. 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:

11. 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

12. 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

13. 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

14. 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

15. AVERAGE DOWNTIME:

17. 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

18. SYSTEM –A DAY IN THE PROCESS Frozen Cookies Commercial Cookies

19. 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

20. 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.

21. 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.

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