BRIDGET EGGERS, RICHARD LATHAMTYLER BRENT, VALERIA GONZALEZ
Frozen Cookies Capacity Increase
Presentation Goals
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Project Scope
Establish synchronized flow between scaling, mixing, dividing and packaging steps in frozen cookie production for optimal productivity.
Scaling
Mixing StageDividing
Defining Current State
Undefined variability in and around the production line There is a bottleneck between the mixing and dividing steps Underutilization of resources Scheduling issues Use of overtime Lack of standardization Production delays
Frozen Cookie Demand 2013
Dad's
Cooki
e Puc
ks n
o nu
ts
ult c
hchp
no
nuts
ult c
hchp
nut
s
Cooki
e Puc
ks n
uts
suga
r she
et
mac
aroo
nsa
ble
oatm
eal r
aiso
n
pean
ut b
utte
r
snicke
rdoo
dle
chcc
hc ch
unk
0
5000
10000
15000
20000
25000
30000
Dad's
Cookie Pucks no nuts
ult chchp no nuts
ult chchp nuts
Cookie Pucks nuts
sugar sheet
macaroon
sable
oatmeal raison
peanut butter
snickerdoodle
chcchc chunk
Other
Data Collection
Data Sources
Frozen Bakery Tracking Form- Actual Packaging Times (Cakes, Muffins, Doughnuts, Frozen Cookies)
APV Commercial Oven Tracking Form Actual Commercial Oven Times (Commercial Cookies)
Frozen Bakery Tracking Form Actual Dividing Times (Frozen Cookies)
Weekly production schedules for commercial cookies Scheduled Commercial Oven Times (Commercial Cookies)
Weekly production schedules for frozen cookies Scheduled Packaging Times (Cakes, Muffins, Doughnuts, Frozen
Cookies)Frozen Cookie Cycle Times and RecipesCookie Capacity & Capability
Seasonal Demand Data
0
1000
2000
3000
4000
5000
6000
7000
8000
Frozen Cook-iesCakesMuffinsDonuts
Case
s
Number of Observations
10 11 12 1 2 3 4 5 6 7 8 9 100
2
4
6
8
10
12
14
Process Observations
Time of day
Num
ber
of
vis
its
Commercial MixingCommercial DividingFrozen Pre Scaling
Commercial MixingCommercial DividingFrozen Mixing
Frozen Dividing
Analysis
Actual vs. Scheduled Commercial Oven Production Time
Mixing
Mixing Station
TimeCumulative
Time Task Time Task 14:15 0:00:00 14:20 0:05:02 0:05:02 Setting up station NVA14:25 0:05:20 0:00:18 Add ingredient VA14:25 0:05:28 0:00:08 Walk/Open/Fold NVA14:25 0:05:38 0:00:10 Add ingredient VA14:25 0:05:42 0:00:04 Walk/Open/Fold NVA14:25 0:05:55 0:00:13 Add ingredient VA14:26 0:06:05 0:00:10 Walk/Open/Fold NVA14:26 0:06:40 0:00:35 Add ingredient VA14:27 0:07:51 0:01:11 Mix VA14:31 0:11:52 0:05:12 Grab more ingredients NVA14:33 0:13:14 0:01:22 Add ingredient VA14:34 0:14:05 0:00:51 Walk/Open/Fold NVA14:34 0:14:12 0:00:07 Add ingredient VA14:34 0:14:22 0:00:10 Walk/Open/Fold NVA14:34 0:14:29 0:00:07 Add ingredient VA14:34 0:14:54 0:00:25 Walk/Open/Fold NVA14:35 0:15:01 0:00:07 Add ingredient VA14:35 0:15:09 0:00:08 Walk/Open/Fold NVA14:35 0:15:21 0:00:12 Add ingredient VA14:39 0:19:20 0:04:11 Mix VA14:39 0:19:45 0:04:24 Grab more ingredients NVA14:40 0:19:58 0:00:13 Add ingredient VA14:40 0:20:04 0:00:06 Walk/Open/Fold NVA14:40 0:20:22 0:00:18 Add ingredient VA14:40 0:20:29 0:00:07 Walk/Open/Fold NVA14:40 0:20:47 0:00:18 Add ingredient VA14:40 0:20:52 0:00:05 Walk/Open/Fold NVA14:41 0:21:00 0:00:08 Add ingredient VA14:41 0:21:07 0:00:07 Walk/Open/Fold NVA14:41 0:21:19 0:00:12 Add ingredient VA14:42 0:22:40 0:01:21 Mix VA14:44 0:24:53 0:02:13 Dump dough NVA14:47 0:27:07 0:02:14 Move troughs, cover and label them NVA
Percentage of VA vs. NVA per observation1 2 3 4 5 Average
VA 0.4075 0.4130 0.5793 0.5843 0.5942 0.5157NVA 0.5925 0.5870 0.4207 0.4157 0.4220 0.4876
51%49%Value added time
Non-value added time
Planned vs. Actual Mixing Time
1 2 3 4 5 6 7 80:00:00
0:10:00
0:20:00
0:30:00
0:40:00
0:50:00
1:00:00
Sub Shop Cookies (Oct 1st and Oct 3rd)
Sub Cookie (Nut)Sub Cookie (No Nut)Scheduled Cycle Time
Batch
Tim
e (
min
ute
s)
Planned vs. Actual Mixing Time
1 2 3 4 5 6 7 80:00:00
0:10:00
0:20:00
0:30:00
0:40:00
0:50:00
1:00:00
Ultimate Cookies (Oct 1st and Oct 3rd)
Ultimate w NutsUltimate (No Nut)Scheduled w NutsScheduled (No Nut)
Batch
Tim
e (
min
ute
s)
Dividing
Dividing Station
The following timeline shows value-added (colored sections) vs. non-value added (white sections) activities.
Each color represents one troughThere is not continuous flow within the
station
Planned vs. Actual Dividing Time
The following graph shows the scheduled vs. the actual time for frozen cookies on the divider
Actual vs. Scheduled Packaging Times
Conclusions
Variability derives from other production lines that are sharing resources Mixer with Commercial cookies Blast Freezer with Cakes, Muffins & Doughnuts
Changeover time is not accounted for in scheduling
Planned vs Actual cycle times are not consistent
Labor intensive tasks on Mixer yields high variability in cycle times
Unplanned production adjustments affect scheduled availability of shared resources
Open items & future work
Observation on the pre-scaling stationFurther analysis on commercial line change
over timesFurther analysis on variability in the cake,
muffin and doughnut lines Identify most effective and feasible solutions
concepts
Q& A
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