Sponsored by Wegmans R09710 - Modern Food Processing and Bakery Technology for Lean Production...

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

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


IV

Process Improvem

ent


Waste Reduction

Set-up Time and



Safety


and Safety Analysis



Sustain


Areas

Ergonomic


Areas

Material Handling



Handling Flow


Procedures

Controls



Create a Tracking

System for Metrics

Visual Controls and


Time)

Improve Metrics

Equipment


Procedure




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


IV

Process Improvem

ent


Waste Reduction

Set-up Time and



Safety


and Safety Analysis



Sustain


Areas

Ergonomic


Areas

Material Handling



Handling Flow


Procedures

Controls



Create a Tracking

System for Metrics

Visual Controls and


Time)

Improve Metrics

Equipment


Procedure




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


IV

Process Improvem

ent


Waste Reduction

Set-up Time and



Safety


and Safety Analysis



Sustain


Areas

Ergonomic


Areas

Material Handling



Handling Flow


Procedures

Controls



Create a Tracking

System for Metrics

Visual Controls and


Time)

Improve Metrics

Equipment


Procedure




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.


IV

Process Improvem

ent


Waste Reduction

Set-up Time and



Safety


and Safety Analysis



Sustain


Areas

Ergonomic


Areas

Material Handling



Handling Flow


Procedures

Controls



Create a Tracking

System for Metrics

Visual Controls and


Time)

Improve Metrics

Equipment


Procedure




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?

Sponsored by Wegmans R09710 - Modern Food Processing and Bakery Technology for Lean Production...

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