Mars CandyVALUE STREAM MAPPING

GROUP 6

JERRY, JESSICA, SHAWNEE

Introduction

Data & Processes

Mars Value Steam

Key Take-Aways

Value Stream Mapping

Value stream mapping is a tool that visually depicts a product’s current flow of materials through the entire supply chain

to improve the process by focusing on lean production.

Introduction

Data & Processes

Mars Value Steam

Key Take-Aways

Introduction

Data & Processes

Mars Value Steam

Key Take-Aways

In order to meet increasing demand for its Peanut M&M’S and bite-size SNICKERS, in 2014 the company built its first brand-new manufacturing plant in North America in 35 years, which is Food Engineering’s 2015 Plant of the Year Award winner.

Introduction

Data & Processes

Mars Value Steam

Key Take-Aways

Topeka Manufacturing Facility

•Currently houses 2 different value chains.

• Bite-size Snickers- modeled after the designs of the pre-existing lines• Peanut M&M’s- is constantly evolving to be more efficient

•Has the capability to house 5 value streams to support future expansion

Introduction

Data & Processes

Mars Value Steam

Key Take-Aways

Automation and The Process•The M&M’s and Snickers processes are entirely automated, and integrated with all the other automated systems in the value stream.

•Both processes receive their chocolate supply from two different in house mixing and refining units. These units receive cocoa powder from and enclosed dry conveyance system. The liquid chocolate is then pumped throughout the plant to the processes that require them.

Automation and The Process Continued…•The facility can accommodate up to 49 rail cars carrying cocoa, eggs and sugar. All railcars are offloaded using an entirely automated system that keeps the ingredients completely sealed from the environment while they are moved to holding vessels.

•Despite the vastness of the plant the just-in-time facility can only accommodate 3 days’ supply of major ingredients.

Peanut M&M’S Value Stream

•Sealed dry conveyors remove whole raw peanuts from the storage bins and deposit them directly into the roaster. An air-handling system keeps the air in this room clean and separate from the air in other rooms.

•Next they are conveyed to the M&M’S process lines where they are sprayed with chocolate, then coated in chocolate.

•The chocolate covered peanuts then proceed to the painting process where the colors, waxes and other coatings are applied.

Introduction

Data & Processes

Mars Value Steam

Key Take-Aways

Peanut M&M’S Value Stream Cont.•Finally the candy goes into a mixing system so the colors can be mixed to the assorted variety they are known for.

•From the mixing system, the candy is transported to the “printing” system where the candies receive a lower-case “m” on each piece.

•After they receive their perfect m and automatic system weighs out the candy to exact specification according to each package size. They are then filled, sealed, put into cartons and palletized by more machines.

Introduction

Data & Processes

Mars Value Steam

Key Take-Aways

Facility Design

“The movement and traffic patterns of materials, products and people—along with the layout of the equipment—were designed to protect against potential contamination sources. For instance, unidirectional process flow from raw receiving to final product is used to avoid cross-contamination. Minimal warehousing and storage of raw materials to finished product is managed in a JIT manner to avoid accumulation of material in hard-to-clean areas. Allergen-related materials and operational areas are handled through segregation, restricted access through personnel hygiene points and HVAC pressurization control.”

•Labs, Wayne. "Plant of the Year: Mars Chocolate Is Lean, Green and Poised for Growth." Food Engineering. Foodengineeringmag.com/, 6 Apr. 2015. Web. 14 Apr. 2015. <http://www.foodengineeringmag.com/articles/93728-mars-chocolate-lean-green-and-poised-for-growth>.

Introduction

Data & Processes

Mars Value Steam

Key Take-Aways

Safety MeasuresLiquid processes and flows are piped and processed internally without exposure to the room environment.

Dry ingredients are handled by closed conveyor systems from storage to destination, whether they originate in super sacks or from truck or railcar.

Processes like candy or chocolate coating happen inside equipment, safely isolated from airborne contaminants.

Open product conveyance also is minimized throughout the facility.

The air is filtered and clean in areas where finished candy may be exposed to room air

Product processing/packaging lines are kept free and clear of any overhead utility lines.

Introduction

Data & Processes

Mars Value Steam

Key Take-Aways

Competitive benefits ofvalue stream mapping

1. Provides greater customer value

2. Solves – Quality, Cost, Delivery, Safety, Morale – problems

3. Generates cross functional teamwork‐

4. Puts one ahead of the competition

5. Develops its leadership team

6. Allows for experimentation with different approachesto find the most ideal process that combines the bestparts of each approach

Introduction

Data & Processes

Mars Value Steam

Key Take-Aways

References•"Lean Principles | Lean Thinking | Value Stream | Flow." Business Excellence Lean Sigma. Businessexcellence, n.d. Web. 14 Apr. 2015. <http://businessexcellence.ie/lean-principles/>.

•Principles in Action Summary 2013. Principles in Action Summary. Mars.com, 31 Mar. 2013. Web. 14 Apr. 2015. <http://www.mars.com/global/assets/doc/pia_exec_2013/Mars_PIA_Highlights_2013_EN_report.pdf>.

•Labs, Wayne. "Plant of the Year: Mars Chocolate Is Lean, Green and Poised for Growth." Food Engineering. Foodengineeringmag.com/, 6 Apr. 2015. Web. 14 Apr. 2015. <http://www.foodengineeringmag.com/articles/93728-mars-chocolate-lean-green-and-poised-for-growth>.

The End