View
33
Download
0
Category
Preview:
DESCRIPTION
Improvement Plan updates po. Richard Latham Bridget Eggers Tyler Brent Valeria Gonzalez. Presentation Objectives. Summarize what was achieved last semester Present project timeline Updates on activities Mixing Prep Activities Mixing Clean Up Kaizen Scaling Process Improvement - PowerPoint PPT Presentation
Citation preview
IMPROVEMENT PLAN UPDATESPORichard Latham Bridget EggersTyler BrentValeria Gonzalez
PRESENTATION OBJECTIVES Summarize what was achieved last semester Present project timeline Updates on activities
Mixing Prep Activities Mixing Clean Up Kaizen Scaling Process Improvement Operations Management Standard Work Implementation
MSD I SUMMARY
PROJECT PLAN – MSD II
ENGINEERING REQUIREMENTS
MIXER WORKER JUSTIFICATION PROJECT Objective:
To make a decision about whether a second operator is justifiable in the frozen cookie mixer process (for cookies with inclusions).
Engineering Requirements: Characterization of all process steps Throughput Implemented solutions are consistent across all crews and shifts Tools that make system run smoothly Management approval
Test Method: Cycle time improvement
MIXER WORKER JUSTIFICATION PROJECT Current Progress:
Videos taken for Dads, Ultimate w/ nuts, Sub Shop w/ nuts Process analysis completed for one operator Job elements created for two workers based off reasonable
assumptions Job element comparison charts created for one worker vs two
workers
Dads
1 operator26 min 15 sec
2 operators15 min 9 sec
73% increase
Sub Shop W/ Nuts
1 operator33 min 34 sec
2 operators17 min 38 sec
90% increase
Ultimate W/ Nuts
1 operator27 min 50 sec
2 operators16 min 8 sec
72% increase
MIXER WORKER JUSTIFICATION PROJECT Next Steps:
Experiment with two workers Create standard job element sheet for two workers using operator
feedback Present findings to management
SANITATION KAIZEN Objective:
Create a system that allows the sanitation employee to be at the mixer at the right time.
Engineering Requirements: No food safety, ergonomics, quality impacts Throughput Characterization of all process steps Implemented solutions are consistent across crews and shifts Tools that make system run smoothly Management approval
Test Method: Mixer wait time per week (see Mixer Operator Time Sheet)
SANITATION KAIZEN Current Progress:
Interviewed Jim Roode about sanitation processes Agreed that sanitation can work on a schedule Suggested ideal state would be a one to two hour notice Sanitation employee will fill out sanitation section of the Mixer Operator
Time Sheet Next Steps:
Map information flow scenarios for mixer sanitation Collect data on sanitation cycle time Update schedule to include sanitation Present findings to management
RECIPE MODIFICATION PROJECT Objective:
Increase usability of recipe by removing the need for calculations to find the number of bags/boxes needed.
Engineering Requirements: Characterization of all process steps Implemented solutions are consistent across crews and shifts Tools that make system run smoothly Sustainable solution methods Management approval
Test Method: Does the sheets make sense to the operator? - Yes/No Are the sheets being utilized regularly? - Weekly Team Leader Audit
OPERATIONS MANAGEMENT MIXING
Objective: Make mixer its own resource and develop a single daily mixer schedule.
Engineering Requirements: Characterization of all process steps Tools that make system run smoothly Implemented solutions are consistent across crews and shifts Management approval
Test Method: Planned vs Actual number of batches (see Mixer Operator Time
Sheet)
OPERATIONS MANAGEMENT MIXER Current Progress:
Collecting mixer cycle times for frozen and commercial cookies
Created preliminary mixing schedule Down time, reason, sanitation
Trained mixer operators on mixer tracking sheet
Next Steps: Collaborate with frozen and commercial
schedulers on mixer schedule Test and validate schedule
OPERATIONS MANAGEMENT DIVIDER
Objective: Create changeover matrix for divider for use in scheduling.
Engineering Requirements: Characterization of all process steps Tools that make system run smoothly Implemented solutions are consistent across crews and shifts Management approval
Test Method: Was changeover time accounted for in the weekly schedule? – Yes/ No Does the matrix clearly provide the changeover time between
different cookie types? - Yes/No
OPERATIONS MANAGEMENT DIVIDER
Current Progress: Collect reasons for changeover
Next Steps: Collect times for changeover Create changeover matrix Present matrix to scheduler 125303 197668 58940 372378 379705 357632 313034 126403 282062
Sub Shop w nuts
Sub Shop Dads old
wayDads
new wayUltimate
Ultimate w nuts
MachineCookie Pucks-
W/Nuts
Cookie Pucks-No
Nuts
Frz Choc Chip
CookyTO BE DISCD
ULT Choc Chip
SheetsNEW
Frz Ult ChChp Cooki 1.1oz
Frz Ult ChChp
Nuts 1.1oz
Frz Chc Chc
Chunk Cky 1.1
Frz Oatmeal
Raisin 1.1oz
Frz Pnut Btr
Cookie 1.1oz
Frz Snickerd
oodle Pucks
125303Sub Shop
w nutsCookie Pucks-
W/NutsW/U x
197668 Sub Shop Cookie Pucks-
No NutsW/U x
58940Dads old
way
Frz Choc Chip Cooky
TO BE DISCDW/U x
Dads new way
ULT Choc Chip SheetsNEW
W/U x
372378 UltimateFrz Ult ChChp Cooki 1.1oz
W/U x379705
Ultimate w nuts
Frz Ult ChChp Nuts 1.1oz
W/U x357632
Frz Chc Chc Chunk Cky 1.1
W/U x
To
From
Frozen Cookies Changeover Matrix (Time to change)
Products
STANDARD WORK IMPLEMENTATION Objective:
Create work instructions for revised process improvements Engineering Requirements:
Characterization of all process steps Implemented solutions are consistent across crews and shifts Tools that make system run smoothly Sustainable solution methods Management approval
Test Method: Do the updated work instructions make sense to the worker? – Yes/No Are they being utilized regularly? – Weekly Team Leader Audit
DISCUSSION
Recommended