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Sponsored by Wegmans
R09710 - Modern Food Processing and Bakery Technology for Lean Production
Systems
Levi StuckEvan DeCotisKate Gleason Stephanie RagerCecilia EnestromBruno CoelhoErik Webster
Project Description and Overview
Mission Statement: The Modern Food Processing and Bakery Technology for Lean Production
Systems project roadmap lays out a series of projects for the Wegmans bakery facility that will improve major aspects of the company's processes. Each project may be used as a tool to educate RIT students in Lean process improvement techniques and can be iterated many times in the future to provide additional benefits to both Wegmans and the RIT Senior Design Program.
Project Objective: Identify and implement improvement projects throughout different areas
within the Wegmans bakery facility. This project family will examine several production lines within the facility and present improvement projects that can be performed on each line. The necessary projects and improvement techniques will vary among the production lines because they all operate independently. Some projects may include: Lean improvement, safety and ergonomics, material handling, layout reconfiguration and equipment upgrades.
Business Goals and Deliverables
Identify specific improvement projects within the facility
Develop production metrics to evaluate improvements based on the needs and goals of each production line
Implement improvement projects to reduce costs associated with wastes and inefficiencies within the facility
Properly document all improvements and process changes as these projects are implemented
Create process documentation where it is currently lacking
Project Stakeholders
Primary Customers: Wegmans Facility and Employees Scott Young, Manufacturing Engineering Manager Chris Isaacson, Industrial Engineer
Other Stakeholders: John Kaemmerlen, Faculty Advisor Mark Smith, RIT Senior Design
Affinity DiagramLeanProcess Analysis 5S Program 5S Policy Kaizen SystemFind the Herbie Station Standardization Seasonal AccommodationsERP - Metrics, Utilization Seasonal Product ProceduresEstablish Usable Metrics Flow (Apparent) Lean Production MetricsPoor Flow Across Facility Performance Metrics Improved FlowPerformance Metrics Visual Aids Standardization for ChangeoversTIMWOOD Metrics Implement a Pull System StandardizationValue Stream Mapping Standards for Processes No Set StandardsLine Rates Models, Assess Daily Performance Lean Training ProgramImprove Flexibility with Seasonal Products
SafetyImproved Ergonomics Create Ergo TeamSafety Ergonomics Ergonomic IssuesErgonomic Evaluation
Knowledgeable Resources
Proper Labor AllocationImproved Labor StaffingMore Engineering Resources
Material Handling/Logisti
csLots of Manual TransportMaterial HandlingImproved Material Handling Logistics AnalysisIn-house Logistic IssuesLogistics in Each Area
FacilitySpace Constraints Equipment UpgradesUpdated Facilities Plan and LayoutAutomation
Set-upSanitation ProceduresSanitation ChangeoversChangeovers/Set-up times
Preventative Maintenance
Preventative Maintenance ProceduresMaintenancePreventative Maintenance
PackagingImproved PackagingPackaging IssuesStandardization in Weight
Change Manufacturing Mindset
Quality ControlInterdepartmental
Communication
Objective TreeResources Scope Economics Technology
People:Senior Design
StudentsWegmans Engineers
Documentation for Reiteration
of Projects
Three to Five Years ROI for
Capital Investments
Wegmans Current Bakery Machinery and Product Lines
Equipment:Production Lines at
WegmansToyota Production
Systems Lab
Useful for Engineers
Interested in Process
Improvements
Cost of Time and
Production to Implement Changes
Mostly ME/IE Content
Time:22 Weeks per Project
Small Kaizen Projects to
Start, Larger Projects in the
Future
Low to No Direct Costs
for Most Projects
Easy to Implement for
Wegmans Employees and
Engineers
Project RoadmapTRACK Phase I Phase II Phase III Phase
IV
Process Improvem
ent
Identify Flow and Current State
Waste Reduction
Set-up Time and
Changeover Reduction
Improve Layout Design
Safety
Improved Documentation
and Safety Analysis
Implement 5S:Sort, Set in
order, Shine, Standardize,
Sustain
Ergonomic Projects at High Risk
Areas
Ergonomic
Projects at Low Risk
Areas
Material Handling
Identify Material Handling Waste
Standardize Material
Handling Flow
Improve and Implement Material Handling
Procedures
Controls
Track Current Metrics,
Implement Current Metric Documentation
Create a Tracking
System for Metrics
Visual Controls and
Documentation for Metrics and System Status (Real-
Time)
Improve Metrics
Equipment
Analyze Current Equipment and Maintenance
Procedure
Create and Implement
Documentation for Equipment
Update Out-of-Date (bottleneck) Equipment
Project RoadmapTRACK Phase I Phase II Phase III Phase
IV
Process Improvem
ent
Identify Flow and Current State
Waste Reduction
Set-up Time and
Changeover Reduction
Improve Layout Design
Safety
Improved Documentation
and Safety Analysis
Implement 5S:Sort, Set in
order, Shine, Standardize,
Sustain
Ergonomic Projects at High Risk
Areas
Ergonomic
Projects at Low Risk
Areas
Material Handling
Identify Material Handling Waste
Standardize Material
Handling Flow
Improve and Implement Material Handling
Procedures
Controls
Track Current Metrics,
Implement Current Metric Documentation
Create a Tracking
System for Metrics
Visual Controls and
Documentation for Metrics and System Status (Real-
Time)
Improve Metrics
Equipment
Analyze Current Equipment and Maintenance
Procedure
Create and Implement
Documentation for Equipment
Update Out-of-Date (bottleneck) Equipment
Process ImprovementObjectives:• Identify and document current flow of material through the lines• Identify areas creating the most waste and implement reduction techniques• Identify longest setup/ changeover times and reduce it
Potential Projects Provided by Wegmans:• Fresh Roll Line Shrink Reduction• ParBake Shrink Reduction• Pastry Area improved layout
Constraints:• Implementing the change, workers against change
Resources:• Industrial Engineers: analyze flow, find waste, lean production techniques• Mechanical Engineers: design of alternatives in setup reduction
Project RoadmapTRACK Phase I Phase II Phase III Phase
IV
Process Improvem
ent
Identify Flow and Current State
Waste Reduction
Set-up Time and
Changeover Reduction
Improve Layout Design
Safety
Improved Documentation
and Safety Analysis
Implement 5S:Sort, Set in
order, Shine, Standardize,
Sustain
Ergonomic Projects at High Risk
Areas
Ergonomic
Projects at Low Risk
Areas
Material Handling
Identify Material Handling Waste
Standardize Material
Handling Flow
Improve and Implement Material Handling
Procedures
Controls
Track Current Metrics,
Implement Current Metric Documentation
Create a Tracking
System for Metrics
Visual Controls and
Documentation for Metrics and System Status (Real-
Time)
Improve Metrics
Equipment
Analyze Current Equipment and Maintenance
Procedure
Create and Implement
Documentation for Equipment
Update Out-of-Date (bottleneck) Equipment
SafetyObjectives:• Look at current documentation for safety incidents and complaints• Create new and improved documentation• Create safety training for employees for reporting incidents or for safe procedures
Potential Projects Provided by Wegmans:• Work with the Ergonomics Team• Improve Ergonomics of Pastry Area
Constraints:• May not be able to update current equipment• Unable to adjust any lifted weight
Resources:• Industrial Engineers: analyze ergonomic factors, develop alternatives• Mechanical Engineers: design of alternatives
Project RoadmapTRACK Phase I Phase II Phase III Phase
IV
Process Improvem
ent
Identify Flow and Current State
Waste Reduction
Set-up Time and
Changeover Reduction
Improve Layout Design
Safety
Improved Documentation
and Safety Analysis
Implement 5S:Sort, Set in
order, Shine, Standardize,
Sustain
Ergonomic Projects at High Risk
Areas
Ergonomic
Projects at Low Risk
Areas
Material Handling
Identify Material Handling Waste
Standardize Material
Handling Flow
Improve and Implement Material Handling
Procedures
Controls
Track Current Metrics,
Implement Current Metric Documentation
Create a Tracking
System for Metrics
Visual Controls and
Documentation for Metrics and System Status (Real-
Time)
Improve Metrics
Equipment
Analyze Current Equipment and Maintenance
Procedure
Create and Implement
Documentation for Equipment
Update Out-of-Date (bottleneck) Equipment
Material HandlingObjectives:• Identify and document current material handling procedures• Identify material handling waste (excess walking, manual)• Develop alternatives in order to eliminate waste
Potential Projects Provided by Wegmans:• Create standardized bake racks to be used throughout entire facility• Fresh Bread & Roll Scaling Project- develop method to “sift and screen” materials during the scaling process
Constraints:• May not be able to update current equipment• Unable to automate a manual process
Resources:• Industrial Engineers: analyze current system and documentation, identify waste• Mechanical Engineers: design of alternatives
Project RoadmapTRACK Phase I Phase II Phase III Phase
IV
Process Improvem
ent
Identify Flow and Current State
Waste Reduction
Set-up Time and
Changeover Reduction
Improve Layout Design
Safety
Improved Documentation
and Safety Analysis
Implement 5S:Sort, Set in
order, Shine, Standardize,
Sustain
Ergonomic Projects at High Risk
Areas
Ergonomic
Projects at Low Risk
Areas
Material Handling
Identify Material Handling Waste
Standardize Material
Handling Flow
Improve and Implement Material Handling
Procedures
Controls
Track Current Metrics,
Implement Current Metric Documentation
Create a Tracking
System for Metrics
Visual Controls and
Documentation for Metrics and System Status (Real-
Time)
Improve Metrics
Equipment
Analyze Current Equipment and Maintenance
Procedure
Create and Implement
Documentation for Equipment
Update Out-of-Date (bottleneck) Equipment
ControlsObjectives:• Track and implement current metrics and documentation• Create a tracking system for metrics• Visual controls and documentation for metrics in real-time• Improve metrics for more detailed tracking Constraints:• No current metric system in place • Lack of historical data
Resources:• Industrial Engineers: Analyze areas where tracking is needed most• Mechanical Engineers: Construction of control systems• Electrical/Computer Engineers: DAQ system for tracking, electronics of control systems.
Project RoadmapTRACK Phase I Phase II Phase III Phase
IV
Process Improvem
ent
Identify Flow and Current State
Waste Reduction
Set-up Time and
Changeover Reduction
Improve Layout Design
Safety
Improved Documentation
and Safety Analysis
Implement 5S:Sort, Set in
order, Shine, Standardize,
Sustain
Ergonomic Projects at High Risk
Areas
Ergonomic
Projects at Low Risk
Areas
Material Handling
Identify Material Handling Waste
Standardize Material
Handling Flow
Improve and Implement Material Handling
Procedures
Controls
Track Current Metrics,
Implement Current Metric Documentation
Create a Tracking
System for Metrics
Visual Controls and
Documentation for Metrics and System Status (Real-
Time)
Improve Metrics
Equipment
Analyze Current Equipment and Maintenance
Procedure
Create and Implement
Documentation for Equipment
Update Out-of-Date (bottleneck) Equipment
EquipmentObjectives:• Identify outdated and/or bottleneck equipment• Research new alternatives or upgrades• Implement feasible equipment changes and upgrades along with preventative maintenance solutions
Potential Projects Provided by Wegmans:• Creation of preventative maintenance procedures for bakeshop equipment Constraints:• Large scale custom assembly lines• Expensive• Integration issues• High volume of product so durability is crucial
Resources:• Industrial Engineers: analyze current system and documentation, identify waste• Mechanical, Electrical, Computer Engineers: design of alternatives
Project Constraints/Restrictions
Over Utilization of Industrial Engineering ResourcesLean workCustomer needs fulfillment
Process ImprovementLarge amount of observation timeImplementation delays6 teams = 42+ people on mfg floor
(Manageable?)
Questions?