Fresh Bread and Roll Scaling RoomMSD II Final PresentationErik Webster, Cecilia Enestrom, Kate Gleason, Grant Garbach, Andrew TsaiMay 15th, 2009

Agenda Project Deliverables from Week 3

Review of deliverables completed during MSD I Layout

Options Final Design Implementation Status

Replenishment Process Design Process Implementation Status

Air Quality Improvement Equipment Options Final Design

Project Deliverables from Week 3 AutoCAD drawings for the layout of the scaling area Analysis of equipment needs for sifting and screening

dry ingredients Analysis of the current process ergonomics and

necessary improvements Standardized work practices that will reduce the

process steps, time, cost, and/or labor requirements Application of lean principles to reduce process waste Detailed implementation plans that will allow for the

realization of these improvements

Project Deliverables from Week 3 AutoCAD drawings for the layout of the scaling area Analysis of equipment needs for sifting and screening

dry ingredients Analysis of the current process ergonomics and

necessary improvements Standardized work practices that will reduce the

process steps, time, cost, and/or labor requirements Application of lean principles to reduce process waste Detailed implementation plans that will allow for the

realization of these improvements

Sifting & Screening Equipment Update

SWECO Separators family of machine sizes

Machine Diameter (inches)

Spout diameter (inches)

Square feet of screen surface area*

Motion Generator Horse Power

Maximum Discharge Spout Capacity** in Cubic Feet per Minute (CFM)

Theoretical spout discharge capacity for a free flowing material weighing 45 lbs per cu ft in lbs/min(ppm)

Actual discharge capacity for stone ground wheat based on the 2-6-09 tested rate of 13.5 lbs per minute through 4 mesh (4.75 mm opening)

18 3 1 0.25 13.5 ppm( =0.3 cfm )

24 2 0.33 30 6 4 0.5 2.1 cfm 95 ppm 54 ppm ( =1.2

cfm) 40 8 6 0.5 2.9 cfm 131 ppm 81 ppm ( =1.8

cfm) 48 8 10 2.5 3.2 cfm 144 ppm 135 ppm (= 3

cfm) 60 15 2.5 72 23 5

Sifting & Screening Equipment Update Determined products that could be sifted

Only dry products Either Mesh 4/Mesh 10 or cannot be sifted

40% actual difference in throughput 40” vs 48” Save footprint size Limits target growth 40” cannot handle 2 of largest size bags

Allergen Issue Determined by Wegmans quality to not be an issue

Recommended washing of the equipment at regular intervals

Ergonomics Review

Recommendations were made to: Eliminate lifting scaling bins onto the

third shelf of rolling carts. Avoid scaling workers lifting bags from

the second rack shelf.

Project Deliverables from Week 3 AutoCAD drawings for the layout of the scaling area Analysis of equipment needs for sifting and screening

dry ingredients Analysis of the current process ergonomics and

necessary improvements Standardized work practices that will reduce the

process steps, time, cost, and/or labor requirements Application of lean principles to reduce process waste Detailed implementation plans that will allow for the

realization of these improvements

New Layout Option 1

Advantages Enough space

for bin area Closer to

staging area Disadvantages

Lose 30 pallet locations

Possible issues with congestion with fork lift

More motion for workers staging bags on carts

New Layout Option 2

Advantages Only lose 12 pallet

locations Possibility of using

floor level of rack locations 9-14

Minimal congestion from fork lift

Less motion for workers staging bags on carts

Disadvantages Less space for bin

area

New Layout Status Progress

Recommendation of what short term storage area was given Bin area location Ingredient pallet locations

Bin area was moved into short term storage area

Continued Work Storage locations are still being finalized

by Wegmans workers

Project Deliverables from Week 3 AutoCAD drawings for the layout of the scaling area Analysis of equipment needs for sifting and screening

dry ingredients Analysis of the current process ergonomics and

necessary improvements Standardized work practices that will reduce the

process steps, time, cost, and/or labor requirements Application of lean principles to reduce process waste Detailed implementation plans that will allow for the

realization of these improvements

Project Deliverables from Week 3 AutoCAD drawings for the layout of the scaling area Analysis of equipment needs for sifting and screening

dry ingredients Analysis of the current process ergonomics and

necessary improvements Standardized work practices that will reduce the

process steps, time, cost, and/or labor requirements Application of lean principles to reduce process waste Detailed implementation plans that will allow for the

realization of these improvements

Replenishment System Necessary to ensure replenishment is finished

prior to the arrival of daily batch cards so scaling is not postponed Should be a highly visual, easy to use system

Kanban system Cards and post

Replenishment System Design How will the fork truck be able to replenish the

short term storage before 2pm every day?

Replenishment System Design How will the fork truck be able to replenish the

short term storage before 2pm every day? Need to know average daily consumption of each

ingredient in order for the fork truck driver to know which ingredient needs to be replenished each day.

Replenishment System Design How will the fork truck be able to replenish the

short term storage before 2pm every day? Need to know average daily consumption of each

ingredient in order for the fork truck driver to know which ingredient needs to be replenished each day.

How will we determine the average daily consumption levels?

Replenishment System Design How will the fork truck be able to replenish the

short term storage before 2pm every day? Need to know average daily consumption of each

ingredient in order for the fork truck driver to know which ingredient needs to be replenished each day.

How will we determine the average daily consumption levels? Tabletop simulation 22 days of data

Replenishment System Design How will it be communicated to the fork

truck driver which ingredients to replenish each day?

Replenishment System Design How will it be communicated to the fork

truck driver which ingredients to replenish each day? Kanban cards

Replenishment System Design How will it be communicated to the fork

truck driver which ingredients to replenish each day? Kanban cards

Who will be responsible for collecting kanban cards each day?

Replenishment System Design How will it be communicated to the fork

truck driver which ingredients to replenish each day? Kanban cards

Who will be responsible for collecting kanban cards each day? Scaling workers via Kanban post

Location of kanban post

Replenishment System Design How will the scaling workers determine if

the ingredient has hit its kanban level? Ingredient signs will display their kanban level

Replenishment System Design How will the scaling workers determine if

the ingredient has hit its kanban level? Ingredient signs will display their kanban level

Simple for low quantity kanban levels, but how do scaling workers quickly count replenish levels of >10?

Replenishment System Design How will the scaling workers determine if

the ingredient has hit its kanban level? Ingredient signs will display their kanban level

Simple for low quantity kanban levels, but how do scaling workers quickly count replenish levels of >10? Kanban line

Replenishment System Status Progress

Ingredient signs were made with kanban levels Kanban cards have been made

Continued Work Because storage locations are still being finalized,

Kanban cards must also be finalized Kanban lines must be placed on appropriate racks Floor tape needs to be laid around scaling area

Need kanban post Staff training will be done this Wednesday

Project Deliverables from Week 3 AutoCAD drawings for the layout of the scaling area Analysis of equipment needs for sifting and screening

dry ingredients Analysis of the current process ergonomics and

necessary improvements Standardized work practices that will reduce the

process steps, time, cost, and/or labor requirements Application of lean principles to reduce process waste Detailed implementation plans that will allow for the

realization of these improvements

Risks AssessmentRisk Probability Severity Preventative Actions

Fork truck resources are not available for implementation 1 9 Detailed cutover plan with Wegmans

Operators do not comply with storage locations 9 1Locations will be flexible to adjust to the changing

needs of the system. Operator training.

Capacity of room is not sufficient for new system with anticipated future growth

3 3Several layout alternatives will be considered and

simulation to verified capacity

Manual resources not available for implementation 1 9 Detailed cutover plan with Wegmans

Increase in ergonomic and safety risks 3 9Store ingredients to minimize dangerous lifting

using simulation tool

Fork truck work increases 3 9Simulation tool created to verify fork truck

requirements. Research alternatives to fork trucks

Staging area does not have sufficient capacity 1 1Detailed layout with input from floor supervisors

and operators

The shift time for the scaling operator does not decrease or increases 1 9Time estimated using process flow diagram and

walking distances

Leveling kanban system fails due to process variability 3 3 Simulation tool to verify kanban system validity

Fork truck drivers and operators do not comply with kanban levels for the short-term storage area

9 9Simulation tool to demonstrate validity of the

system. Operator training and involvement.

Needed supplies are not available at start of implementation 3 9 Detailed cutover plan with Wegman's

Air Handling System

MSD II

Air Handling System

Customer Needs Assessment Improve Air quality Reduce Air Particulate size Help improve area cleanliness Will not interfere with sifting process Will not violate OSHA or Wegmans guidelines

Custom Designed Air Handling System

Concepts

Mobile Straight up

Segment 1 2

Selection Criteria Weight Rating Notes Wtd Rating Notes Wtd

Size 7% 10 0.70 10 0.70

Stagnation Points 5% 5 0.25 10 0.50

Serviceability 9% 10 0.90 7 0.63

Change Filters 10% 9 0.90 7 0.70

Steel Grade 6% 10 0.60 10 0.60

Painted Surfaces 10% 10 1.00 10 1.00

Geometric Discontinuities 7% 5 0.35 10 0.70

Ability to stay Laminar 10% 6 0.60 10 1.00

Reduce Particulate size 10% 10 1.00 10 1.00

Increase time between Cleanings 20% 7 1.40 10 2.00

Mobile 5% 10 0.50 1 0.05

OSHA 85dB 7% 5 0.35 8 0.56

Washable 8% 7 0.56 7 0.56

Engineers Rating of design feasibility 10% 9 0.90 9 0.90

Safety 13% 9 1.17 9 1.17

Total Score 11.18 12.07

Rank 2 1

Continue? No Yes

1 not important

10 extremely important

Scale

CAD Drawings

Selection Matrix for COTS

IQ Air Honeywell Shick Kason

Segment 1 2 3 4

Selection Criteria Weight Rating Notes Wtd Rating Notes Wtd Rating Notes Wtd Rating Notes Wtd

Size 9% 9 0.81 9 0.81 1 0.09 9 0.81

Go/No Go* 30% 3 0.90 3 0.90 9 2.70 3 0.90

Cost 30% 9 2.70 9 2.70 1 0.30 3 0.90

Reduce Particulate size 9% 9 0.81 9 0.81 9 0.81 9 0.81

Increase time between Cleanings 9% 3 0.27 1 0.09 9 0.81 3 0.27

Meets OSHA standards 9% 3 0.27 3 0.27 9 0.81 9 0.81

Safety 9% 3 0.27 3 0.27 9 0.81 9 0.81Engineers Rating of design

feasibility 9% 3 0.27 3 0.27 9 0.81 3 0.27

Total Score 6.30 6.12 7.14 5.58

Rank 2 4 1 3

Continue? N N Y N

1 Worst *Note: Go no go criteria includes, servicability, ability to change filters, steel grade3 geometric discountinuities, ability to stay laminar, mobile and washable.9 Best

ConceptsAir Handling Equipment Selection Matrix

Scale

Shick Equipment

Recommendations

As a best practice, Wegmans should implement at least one sifting piece of equipment to reduce foreign material. Recommendation for equipment: Sweco

vibratory sifter with Mesh 4 To improve bakery air quality, improve

safety, and reduce health concerns, Wegmans should implement an air handling system equipped with dust collection Recommendation for equipment: Shick

Thank you to..Scott Young John KaemmerlenMike Least Phil BryanChris Isaacson

…And the rest of the staff from Wegmans, Aloi, Shick, and Sweco who made this project possible.