Bake Shop Fresh Bread & Roll Scaling Room P09713 Spring 2009 Sponsors: Scott Young Mike Least Advisors: John Kaemmerlen Phil Bryan IE’s: Cecilia Enestrom Kate Gleason Erik Webster ME’s: Grant Garbach Andrew Tsai Mission Statement: To reduce the process time for measuring dry ingredients for the Wegmans Bake Shop fresh bread and roll scaling workers and explore options for sifting and screening dry ingredients. Motivation: - Primary scaling employee working 10-12 hour shifts - Relocate bin area into short term storage area to decrease walking time for employees Background: - Short-term storage area used for staging 50lb bags of ingredients on carts before mixing - Bin area used for measuring additional amounts of ingredients needed for mixing Ex: If mixing calls for 265 lbs of a certain ingredient, 5 50lb bags are staged on carts, then 15lb of that ingredient is measured at bin area and staged on the same cart. -Scaling workers wasting ~1 hour walking between short-term storage area and bin area -Moving bin area into the short-term storage area creates the need for a standardized replenishment system Additional Information: More information can be found at https://edge.rit.edu/content/P09713/public/Home Short-term storage area Bin area New Layout and Replenishment Time Every day, a fork truck driver replenishes the short-term storage area. The distance from Long-term to short-term storage is about 378 ft and a round trip takes ~ 10 min. It was important to be able to estimate how much time replenishment would take each day. A simulation using ingredient consumption during a 22-day period produced these results: It also provided better insight into the new layout by indicating which ingredients were used in low, medium, and high volumes. This chart shows the results of the NIOSH lifting assessment for lifting scaling buckets onto the shelved carts. Therefore, it was recommended that employees not lift the scaling buckets in excess of 30 lbs higher than the 2 nd shelf. Major deliverable was to move bin area into the short term storage area. Sifting & Screening Equipment Conclusion Company: SWECO Model Number: MX48S88 Kanban System A simple visual system was implemented to communicate to the fork truck driver which ingredients needed replenishment. Process: 1. Pallet goes below the kanban line. 2. Ingredient kanban card is taken to the kanban post. 3. Fork truck driver picks up the kanban cards the following day. 4. Fork truck driver replenishes respective ingredients. Special thanks to the •Wegmans Staﬀ including: •Chris Isaacson •Karen Mulcahy •Terry •Edgar •Paul •Jeﬀ Gambrill from Aloi •Jon Ansley from Boutell Air Handling Equipment Relocating the bin area creates the additional customer need of addressing the air quality of the short term storage area. Several options were explored and the results are

Bake Shop Fresh Bread & Roll Scaling Room

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P09713 Spring 2009. Bake Shop Fresh Bread & Roll Scaling Room. IE’s: Cecilia Enestrom Kate Gleason Erik Webster. ME’s: Grant Garbach Andrew Tsai. Sponsors:Scott Young Mike Least Advisors:John Kaemmerlen Phil Bryan. Mission Statement: - PowerPoint PPT Presentation

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Bake Shop Fresh Bread & Roll Scaling Room

P09713Spring 2009

Sponsors: Scott YoungMike Least

Advisors: John KaemmerlenPhil Bryan

IE’s:Cecilia EnestromKate GleasonErik Webster

ME’s:Grant GarbachAndrew Tsai

Mission Statement: To reduce the process time for measuring dry ingredients for the Wegmans Bake Shop fresh bread and roll scaling workers and explore options for sifting and screening dry ingredients.

Motivation:- Primary scaling employee working 10-12 hour shifts- Relocate bin area into short term storage area to decrease walking time for employees

Background:- Short-term storage area used for staging 50lb bags of ingredients on carts before mixing- Bin area used for measuring additional amounts of ingredients needed for mixing

Ex: If mixing calls for 265 lbs of a certain ingredient, 5 50lb bags are staged on carts, then 15lb of that ingredient is measured at bin area and staged on the same cart.-Scaling workers wasting ~1 hour walking between short-term storage area and bin area-Moving bin area into the short-term storage area creates the need for a standardized replenishment system

Additional Information:More information can be found at https://edge.rit.edu/content/P09713/public/Home

Short-term storage area

Bin area

New Layout and Replenishment Time

Every day, a fork truckdriver replenishesthe short-term storagearea. The distance fromLong-term to short-termstorage is about 378 ftand a round trip takes~ 10 min. It was importantto be able to estimatehow much time replenish-ment would take each day.

A simulation using ingredient consumption during a 22-day period produced these results:

It also provided better insight into the new layout by indicating which ingredients were used in low, medium, and high volumes.

This chart shows the results of the NIOSH lifting assessment for lifting scaling buckets onto the shelved carts.

Therefore, it was recommended that employees not lift the scaling buckets in excess of 30 lbs higher than the 2nd shelf.

Major deliverable was to move bin area into the short term storage area.

Sifting & Screening Equipment Conclusion

Company: SWECOModel Number: MX48S88

Kanban System

A simple visual systemwas implemented tocommunicate to the forktruck driver whichingredients neededreplenishment.

Process: 1. Pallet goes below the kanban line. 2. Ingredient kanban card is taken to the kanban post. 3. Fork truck driver picks up the kanban cards the following day. 4. Fork truck driver replenishes respective ingredients.

Special thanks to the •Wegmans Staff including:

•Chris Isaacson•Karen Mulcahy•Terry•Edgar•Paul

•Jeff Gambrill from Aloi•Jon Ansley from Boutell

Air Handling EquipmentRelocating the bin area creates the additional customer need of addressing the air quality of the short term storage area. Several options were explored and the results are expressed in the following table.