Download presentation
Presentation is loading. Please wait.
Published byJacob Eaton Modified over 9 years ago
1
P09712 Commercial Roll Line Shrink Reduction Evan DeCotis Levi Stuck Ryan Dennison Joseph Fitzery Cinthia Sanchez
2
Project Review Agenda Project Overview Customer Needs and Project Specifications System Design Concept Summary Design Summary System Testing Results Objective Project Evaluation Sustaining Project Gains
3
High Priority Customer Needs
4
Engineering Specifications
5
Systems Design DEFECTS PEOPLE Daily Bias (Inconsistency) Lack of Thoroughness Lack of United Goals Material Handling INFORMATION Isolated Information Often does not Leave the Station Lack of Formal Training Lack of Formalized Data ENVIRONMENT Noise Level Variance in Humidity Variance in Temperature PROCESSES Line Imbalance Standard Work High Variation Reactive Vs. Proactive MACHINESMATERIAL Outdated Adjustability (Analog vs. Digital) Inconsistent Lack of Fine Tuning External Contaminants Inconsistent Dough Mixtures Upgradable
6
Design Concept Line Balancing 1 2 QC Consistency 3 Standardization and Rack Design
7
Line Balancing Implementation Max K-Roll Speeds Standardized procedure Performance Management Guidelines Visible Problems Queuing before and after Proof Box Inconsistent bake times and proof times Ideal Proof Box Time – 50 minutes One K-roll Running – 55 min proof with 3% - 5% defective Two K-rolls Running – 75 min proof with 10% - 12% defective
8
Line Balancing # Rolls per Hr Roll Production vs. Bottleneck Capacity K-Roll 1 K-Roll 2 K-Roll OutputOven Capacity
9
Bottleneck Variables K-Roll Speeds New: 80 or 100 cycles per minute Old: 60 to 80 cycles per minute, variable but set manually K-Roll Dough Balls per Cycle Normally 4, Submarine Rolls use 3 Packages per Pan Ranges from 2 to 8 Bake Time 7 to 22 minutes Pans per Oven Row 4, 5, or 6 pans across Bagger Line Speed 50 to 60 bags per minute, two baggers
10
Line Balancing
12
QC Consistency Implementation Standardized Procedure Visual aids for each product family Visual aid stand mounted on each QC line Performance Management Guidelines Visible Problems Lack of consistency in defect classification Some defects get through QC and sent to customers Some good products are rejected as defects
13
QC Consistency Visual Aid example
14
QC Consistency Visual aid stand design constraints Food grade Simplistic Location Easy removal (1 operator, quickly) Durability Safe 10 different options Hinge Drop down
15
QC Consistency Hinge Design
16
QC Consistency Drop Down Design
17
Standardization and Rack Design Implementation Standardized rack loading and unloading procedure Rack cover design proposal Visible Problems Inconsistent rack loading/unloading Uncooked buns left outside of proof box for long periods of time No current standardized procedures Top tray more subject to direct air flow
18
Standardization and Rack Design Process standardization Reduced non-controlled environment time
19
Standardization and Rack Design Rack cover design constraints Food grade Simplistic Removable Uniform 4 different design options Top Cover design Sleeve design
20
Standardization and Rack Design Top Cover Design
21
Standardization and Rack Design Sleeve Design
22
Results
24
42.13% defect reduction Dry spots still high percentage defect Suggest further proof box analysis
25
Results
26
32.16% defect reduction Reduction a result of slower material handling (Trickle down affect)
27
Objective Project Evaluation
28
Sustaining Project Gains Administrative project monitoring and support Positive reinforcement *Instills operator understanding of project and procedure importance*
29
Questions or comments?
Similar presentations
© 2025 SlidePlayer.com. Inc.
All rights reserved.