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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!