P10712CHEESECAKE PROCESS
IMPROVEMENT
Andreana Crance, Kevin Rodas, Rob Santora, Jeremy Smith, Matt Syska
Meeting Agenda
Brief Project Summary 5 min.Project Statement 5 min.System Overview 10 min.Customer Needs & Engineering Specifications 5 min.Risks & Contingencies 5 min.What we have done so far 20 min.Concept Selection 15 min.Target Specs – How we will measure success 10 min.Improvement Ideas 10 min.MSDI Plan of Action 5 min.
P10712 Cheesecake Process Improvement
The mission for the cheesecake process improvement is to increase the efficiency and effectiveness of cheesecake production in order
to meet customer demand in both quantity and quality of the cheesecakes.
Focusing on:
Worker Safety
Worker Productivity
Efficiency of Process
Proper utilization of equipment
Scrap Reduction
Project Approach
Due to the scattered processes taking place for the cheesecakes, we thought it would be best to break the project into larger categories:
Greasing Crumbing Pre-Tunnel Oven
Mixing, Pouring, Loading Oven Post-Tunnel Oven
Unloading oven, into freezer Slicing Packaging
System Overview
Value Stream Map
Customer Needs & Engineering Metrics
Customer Needs & Engineering Metrics
Customer Needs & Engineering Metrics
Customer Needs & Engineering Metrics
Risks and Contingencies
Risks and Contingencies
Risks and Contingencies
Process Evaluation
WeightGreasing Crumbing Pre-Tunnel
OvenPost Tunnel
Oven Slicing Packaging
Score Score Score Score Score Score
Efficiency 25% 1 3 9 1 9 9
Utilization 25% 1 3 9 3 9 3
Safety 25% 9 3 9 3 3 3
Equipment 10% 3 9 9 3 3 3
Scrap 15% 3 9 1 3 3 9
• Pre process clean up
• Sprayer Calibration
• Human bending
Greasing
Efficiency 1
Labor 1
Ergonomic 9
Equipment 3
Scrap 3
What we have observed in Greasing:
What we have observed in Crumbing:
No Direct Observation as of 10/2/2009
Known Issues: Uneven distribution of crumbs
Leads to scrap issues Manual process Nonconformity of crumb size Crumb displacement at batter drop (pre-oven
load)
Crumbing
Efficiency 3
Labor 3
Ergonomic 3
Equipment 9
Scrap 9
Pre-TunnelPre Oven
Efficiency 9
Labor 9
Ergonomic 9
Equipment 9
Scrap 1
• Cluttered area
• Human bending
• Labor intensive
Post-TunnelPost Oven
Efficiency 1
Labor 3
Ergonomic 3
Equipment 3
Scrap 3
• Cluttered area
• Manual process
• No standards
Slicing Issues 5S issues Labor Utilization Material Handling transitions Scrap Issues Machine maintenance reactive
TPM – Be proactive! Staffing setup Almost identical labels (marble vs. plain) Lack of Quality Check-One instance of packing defective cheesecake Walking 2s spin time for machine Ergonomics – Bending and reaching Putting covers on causes quality issues / lost productivity No monitoring of cheesecake time on floor (out of freezer) Variation in results due to lack of process control
Slicing
Efficiency 9
Labor 9
Ergonomic 3
Equipment 3
Scrap 3
Packaging
• No dedicated labor
•Reaching and bending
•Lack of organization
Packaging
Efficiency 9
Labor 3
Ergonomic 3
Equipment 3
Scrap 9
Overall Issues
No standard procedure No standard location for equipment on floor Improper/inadequate tools used Lack of set schedule for cheesecake process Variable batch sizes Lack of standard quality checks Unnecessary movement (time & ergonomics
concern) Current machines may not be ideal Lack of continuous flow
Concept Selection
Discussion
Target Specifications – Marginal and Target Values
Metric No. Metric Importance Units Marginal Value Target Value1 average labor
bottleneck utilization9 percentage per year >80% >85%
2 risk of injuries 9 (benchmarking unit using NIOSH, etc)
25% reduction of benchmarking unit
75% reduction of benchmarking unit
3 people travel distance 1 % travel distance reduction
10% 25%
4 cycle time / cheesecake (minus bake time)
3 min. 90% of current cycle time
75% of current cycle time
5 number of defective products
3 Percentage scrap 75% of current defect rate
50% of current defect rate
6 number employees on cheesecake process
3 employees One employee reassigned
More than one employee reassigned
7 throughput rate 3 throughput/hour 110% of current value 125% of current value8 process improvement
has full ROI for customer
9 Years 1 Year 0.5 Years
9 Solutions meet Wegmans specific
health code standards
9 Y/N Y Y
10 Cheesecake retains “homemade” feel
9 Y/N Y Y
11 Process changes can meet holiday demand
9 Y/N Y Y
List of Possible Ideas
Efficiency Standardize batch size Continuous flow of process Waste reduction maintenance for
equipment: Dropper, greaser, slicer Standard locations for materials and
equipment
List of Possible Ideas
Scrap Quality Checks: “Defect Board” Calibration of equipment: Dropper, greaser, etc.
Efficiency, Safety Reduce total travel distance: people and
materials
Efficiency, Safety, Equipment Eliminating unnecessary motions, providing
proper tools
List of Possible Ideas
Crumbing - (Labor Utilization, Scrap, Equipment) Automated or assisted “Crumber”
Pre/Post Tunnel Oven - (Scrap, Utilization) Regulate water for baking: volume controlled
and assisted
Packaging - (Scrap, Efficiency, Utilization) Alternative packaging methods
MSDI Plan – Our steps forward
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