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