Design Proposal - Oklahoma State University–Stillwater · Ergonomic/Industrial Ideas PROS: •...

Design Proposal

Brady Brewer Stephen EllerMichelle Jones David Haury

Outline

• Introduction• Business• Communications• Engineering • Radical Ideas• Recommendations• Questions

J-M Farms

• Main Facility – Miami, OK• Established 1973• 5 Satellite Farms• White & Portabella Mushrooms• Cover OK, TX, AK, MS, NM, KS, MO,

IA.

Photo Available at : http://www.jmfarms.com/index.html

Problem

• Problem Statement“Our project is to improve the harvesting and

packaging efficiency at J-M satellite farms. The most important factors affecting design are: ergonomics, cost effectiveness, maintenance, and simplicity.”

• Mission Statement “To provide a quality solution to improve J-M Farm’s

packing efficiency.”

Project Description

• Improve efficiency and quality of mushroom packaging process

• New cart was suggested• We examined the entire packaging process• Process Flow• Machine Design

Current Process

Diagram courtesy of J-M Farms.

Current Process

Industry Analysis

• Premium goods dominate the industry– Emphasis on quality– Consumer behavior

• Industry similar to Tomatoes– Growth in the recent past

Competitive Analysis

• Internal Competition– Among pickers and processes

• External Competition– Regional– National

• Specialization seen amongst the industry

Competitive Analysis

• Monterey Mushrooms

Photo Available at: http://www.montereymushrooms.com/overview.htm

Proposed Business Plan

• Executive Summary– Overview of business– Roadmap to follow

• Industry Analysis• Competitive Analysis

– Emphasis on Internal Competition for picking process

Proposed Business Plan

• S.W.O.T. Analysis• Marketing Strategy

– Will includes Communications plan– Market saturation versus Market Penetration

• Conclusion

Business Plan Impact

Photo Available at : http://www.flashbackinfo.org/images/Walmart_New_Logo.png

Proposed Financial Analysis

• Activity Based Costing– What is it?– Why would you use it over other methods?

• Keep costing for picking process the same• Identify key processes • Cost savings from engineering solution

Communications Plan

• Business-to-Business– Mushroom shoppers are valuable to retailers. The

average shopping basket with mushrooms is double the value of shopping baskets without mushrooms.

• Business-to-Customers– Customers tend to be highly educated and wealthy– Hispanic and Asian purchases increasing– Response to point of source materials

Business-to-Business

• Web page– Quality control– Traceability Statistics– Recycling Efforts

• Flier or Brochure– Quality control– Traceability Statistics– Recycling Efforts– Next Day Service

Business-to-Customers• Web page

– Recipes– Storage and handling procedures– Quality control– Traceability Statistics– Recycling Efforts

• Recipe/Fact Booklet Label– Recipes– Storage and handling tips– Quality control– Traceability Statistics– Recycling Efforts

Photos Available at:http://www.jhbertrand.com/cs_promotionalnut.html

Business-to-Customers

• Recipe Cards– Recipes– Storage and handling procedures

• Fact Cards– Nutritional facts– Storage and handling tips

Photos Available at:http://www.stonewallkitchen.com/Content/images/whl_merch_carousel.jpghttp://www.ccicards.com/product-group.aspx?groupID=6

Engineering

• Interdisciplinary Problem– Food Handling– Industrial Engineering / Ergonomics– Mechanical Design

Engineering Concepts

• Industrial/Ergonomic Ideas– 1. CPM Weighing Station at Satellites– 2. Packing Line at Satellites– 3. Redesign Packaging Process at Main Farm– 4. Redesign/Alter Slicing Line at Main Farm– 5. Temperature/Time/Handling Study

Ergonomic/Industrial Ideas

PROS:• Mushrooms are ready for

shipment at satellites• Decreased work load at main

facility• Increased space at main facility

(focus on slicing)• Test feasibility of a streamlined

processCONS:• Heavy initial cost for satellite• Substantial space requirements

Packaging Line at Satellites

Ergonomic/Industrial Ideas

PROS:• Increase Efficiency• Eliminate redundant

processes• Mitigate lossCONS:• Adjustment required of

employees• Potential production shut

down

Redesign Packaging Process at Main Farm

Ergonomic/Industrial IdeasTemperature/Time/Handling Study

Ergonomic/Industrial Ideas

Engineering Concepts

• Mechanical Design Ideas– 1. Picker Cart with Scales– 2. Packaging Cart (using snap-on lids)

Mechanical Design Ideas

PROS:• Pick by weight, not volume• Better quality, reduced

handling• Shorter time to package

CONS:• Less Flexibility with

increased size• Large capital investment• Increase picker work load

Picker Cart with Scales

Mechanical Design Ideas

PROS:• Ready for shipment at satellites• Increased shelf life• ‘One Touch’ produce• Less work load at main facilityCONS:• Size of cart will likely double• Heavy capital investment• Increase picker work load

substantially• May require alternate RPC

Weighing/Packaging Cart (Snap-on lids)

Radical Ideas

• Team Pay• Value-Added Products• Sell Mushrooms by Count, not by Weight

Team Pay

• Current system pays picker by the pound and packing line workers at an hourly rate

• “You do your job, I do mine” • Mushrooms get dropped

Team Pay

• Team would get paid based on what goes onto the truck

• Increase motivation to decrease waste• Foster teamwork among the members across

the different steps in the harvesting process

Value Added Products

• Sautéed• Fried• Battered

Photo Available at:http://www.poboyexpress.com/menu/foodimg_lg/fried_mushrooms.jpg

Sell Mushrooms By Count

• Mushrooms sold in stores today must meet a certain minimum weight

• Leads to wasted effort in weighing the package multiple times

• Pack by number of mushrooms inside, not by a goal weight

• Print a sticker to display the weight of package so product could still be sold by weight, if mandated

Sell Mushrooms By Count

• Process of packing is simplified because the picker can do it with minimal equipment

• Scale could even be dropped if mushrooms are sold purely by count

• Package directly after picking• Highest quality and freshness

Sell Mushrooms By Count

• Some fresh tomatoes are already being sold by count

• Customers can easily see the quality product

Photo available at: http://www.linpac.com/PageFiles/312/About---tomato-tray.jpg

Sell Mushrooms By Count

Photo available at:http://www.linpac.com/PageFiles/179/Library/Tomato-tray-collage.jpg

Project Recommendation

1. Redesign Packaging Floor2. Temperature/Time/Handling Study3. Weighing / Packaging Cart (Snap on Lids)4. Combination

Questions?

Thank You!