Commercial Roll Line Shrink Reduction

P09712

Levi Stuck Evan DeCotisCinthia SanchezJoseph FitzeryRyan Dennison

Customer NeedsCust.

Need #Importance Customer Need (Description) Comments / Status

    Eliminate TIMWOOD Waste:Some aspects are beyond the scope of this

project. Focus will be on and Transportation and Defects.

CN1 3 a) Transportation WasteAbout 25 minutes on conveyor system. Improve

movement and flow of racks across facility.

CN2 1 b) Inventory Waste

Improvements may be realized by focusing on Transportation and Defects.

CN3 1 c) Motion Waste

CN4 1 d) Waiting

CN5 1 e) Overproduction

CN6 1 f) Overprocessing

CN7 9 g) Defects 5-10% current spoilage rate

    Safety:  

CN8 9 a) Maintain Current Standards Bakery currently meets standards but improving them is not a major focusCN9 3 b) Improving Current Standards

CN10 3 Implementing Flow Improvements Value stream mapping

CN11 9 Standardization of ProcessCurrently there is minimal standardization at the

plant

CN12 9 Introduce Metrics None existing, baseline needs to be established

CN13 3 Visual Aids Changeovers, hot pans, proof box time, etc.

CN14 9 Minimal Cost Do not exceed $5,000

Cust. Need #: Enables cross-referencing with Specifications

Importance: 9=Very Important, 3=Important, 1=Somewhat Important

Specifications

Eng. Spec. #

Importance Source Specification (Description)Unit of

MeasureMarginal

ValueIdeal Value

Comments / Status

ES1 9 CN7 Reduce the number of defects% reduction in

defects25% 75%

ES8 3 CN10, CN11

Throughput will be increased % rate increase 5% 15%

ES2 9 CN7 Categorize defects according to where each defect occurred # of areas >= 2 >= 5K-roll, Proof Box, Oven,

Conveyor, Bagging

ES3 9 CN7 Categorize defects by type # of defect types >= 2 >= 4Rolls not grouped, fingerprints in

dough, dry spots, etc.

ES5 1CN3, CN4,

CN10Reduction in unnecessary human labor

% labor time reduction

20% 75%

ES9 9 CN11 Process time variation will be reduced, standardization Minute range 30-45 10-20Alternative measurement:

standard deviations

ES4 3 CN8, CN9Ensure that design changes do not cause an increase in injuries and/or OSHA recordable incidents

% decrease in injuries

0% 20%

ES10 9 CN12Metrics for X% of all value-added operations (not including material handling)

% of VA operations

50% 100%

ES6 3 CN10Any changes to the line can be taught to someone with prior knowledge to the process within X minutes

Minutes 45 15Minimal time lost due to any

necessary retraining

ES12 3 CN12Data collection (metrics) can be taught to someone with no prior knowledge of process within X minutes

Minutes 45 10 Ability to capture metrics easily

ES11 1 CN12 All metrics can be collected within X minutes or less Minutes 30 min Real timeAllows for quick status reports

on line performance

ES13 3 CN13Intended message portrayed in 5 seconds or less, and provokes the proper response

Seconds <5 <1

ES14 3 CN14 This project will be implemented using little capital investment USD <= $5,000 <= $1,000

Eng. Spec. #: Enables cross-referencing to other documentsSource: Customer need #Importance: 9=Very Important, 3=Important, 1=Somewhat ImportantMarginal Value: Minimum value expectedIdeal Value: Best value possible within realistic expectations

Deliverables

Customer Needs Assessment (Final)

Specifications (Preliminary)

One page project summary (Final)

WBS and team roles (Final)

2 – quarter schedule (Final)

Three week plan (Final)

Benchmarking