P09713 – Bread and Roll Scaling Room

Sponsored by Wegmans

R09710 - Modern Food Processing and Bakery Technology for Lean Production

Systems

Kate Gleason Cecilia EnestromErik Webster

Roadmap 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.

Roadmap 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

Project Improvement Process

TRACK 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

Metrics

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Update Out-of-Date (bottleneck) Equipment

P09713 Bread and Roll Scaling Room Layout and Process Improvement

Line Phase IPhase

IIPhase

IIIPhase

IV

Bread and Roll Scaling Room

Document current process flow and

work practices

Identify areas of process

and layout improveme

nt

Design and implement

the new layout

Design and implement

the new process

procedures

Bread and Roll Scaling Room Layout and Process Improvement

Project Name Bread and Roll Scaling Room Layout and Process ImprovementProject Number P09713RoadmapR09710- Modern Food Processing and Bakery Technology for Lean

Production SystemsStart Term 2008-2End Term 2008-3Faculty Guide Professor Kaemmerlen (Industrial and Systems Engineering Department) Primary Customer Wegmans Facility and EmployeesScott YoungChris Isaacson

Bread and Roll Scaling Room Layout and Process Improvement

Current State• All scaling and measuring of ingredients for the bread

and roll line is performed in the scaling room• Currently the ingredients are stored in 50-lb bags which

are removed from storage racks by hand, measured on the scale, and moved by cart to their respective areas

• Double handling of ingredients is occurring at the two scaling locations

• There is no process for sifting and screening the dry ingredients. This would help reduce debris mixed into the batter

• The layout is less than optimal, processes and work practices are not standardized, and ergonomics is a major concern

Current Scaling Room

Scale and Bucket

Final Scaling Area

New Scaling Area

Bread and Roll Scaling Room Layout and Process Improvement

Mission StatementDocument all work practices and processes for

the bread and roll scaling operation to promote standardized work, develop a new process and layout for the scaling area that is conducive with Lean practices, and design solutions that will create a sifting and screening process that is ergonomically sound and promotes improved work flow.

Bread and Roll Scaling Room Layout and Process Improvement

Key Business Goals/Project DeliverablesDocument all current processes and work

practicesDevelop alternative processes for scaling the dry

ingredientsReduce/eliminate redundancies and double

handling in the processDevelop a process for sifting and screening the

dry ingredientsDevelop the layout for the new scaling areaIdentify other opportunities for improvement in

the scaling area

Bread and Roll Scaling Room Layout and Process Improvement

Assumptions and ConstraintsResources for designing solutions and equipment are

limited but available.Budget will be constrained based on decisions made

by WegmansWegmans’ engineering resources are limited but

availableSpace is limited in the area where the scaling process

will be located and existing materials in the area will be relocated or eliminated

The bread and roll line will be moving to a new location near the new scaling location in the future

Bread and Roll Scaling Room Layout and Process Improvement

Preliminary Customer NeedsRelocate and redesign the layout for the

scaling area near the bread and roll lineImprove the safety and ergonomics of the

processDevelop a process for sifting and screening dry

ingredientsEliminate double handling of dry ingredientsDocument and standardize process proceduresIdentify and implement Lean process

improvements

Preliminary Risk AssessmentCost/Budget

Insufficient funds to design and implement solutions for sifting and screening

Customer ApprovalWegmans does not approve of the solutions

developed by the project teamSpace Restrictions

The area reserved for the new scaling area will not support the process that is developed by the project team

Bread and Roll Scaling Room Layout and Process Improvement

Bread and Roll Scaling Room Layout and Process Improvement Staffing Requirements

Name Discipline

Role

John Kaemmerlen

Faculty Guide

Faculty Guide, will work closely with the team on an on-going basis to facilitate success of project.

Cecilia Enestrom

IE Will serve as Co-Project Manager and focus on the design of the new layout.

Kate Gleason

IE Will serve as Co-Project Manager and concentrate on developing the new scaling processes.

Erik Webster

IE Will serve as Co-Project Manager and concentrate on the design and ergonomics of the new sifting and screening process.

TBD ME Develop new equipment for sifting and screening process.

TBD ME Develop new equipment for new layout and scaling processes.

Bread and Roll Scaling Room Layout and Process Improvement Preliminary Work Breakdown Structure

Person Week 0-1 Tasks

Week 1-2 Tasks

Week 2-3 Tasks

Cecilia Enestrom – Co-Project Manager

Meet to discuss specific team assignments.

Review current layout and new area available in AutoCAD

Take necessary measurements in current and new area

Kate Gleason – Co-Project Manager

Meet to discuss specific team assignments.

Observe current processes and work flow

Document current processes and work flow

Erik Webster –Co-Project Manager

Meet to discuss specific team assignments.

Observe current procedures and qualitatively measure ergonomics

Quantitatively measure the ergonomics of current procedures

ME Read through project located on EDGE website.

Gain an understanding of the process

Measure parameters that are related to design solutions

ME Read through project located on EDGE website.

Gain an understanding of the process

Measure parameters that are related to design solutions

Questions?