P09713 – FRESH BREAD AND ROLL SCALING ROOM

Customer Needs and Product Specifications

Senior Design I: Winter 2008-2009Cecilia Enestrom, Kate Gleason, Erik Webster, Grant Garbach, Andrew Tsai

Customer Needs: Area Layout Long-term storage area Short-term storage area Reduce operator travel distance by

combining the short-term storage and scaling locations

Document and implement the improved layout

Customer Needs: Process Improvement Gain a firm understanding of the current

process through value stream mapping Reduce overall process cycle time

Eliminate double handling of materials Combine the initial and final scaling operation

Determine and reduce current shrink Determine future state value stream map

and inventory management plan based on the improved layout design

Implement a Lean initiative for future improvement

Customer Needs: Ergonomics Work with and assist the existing Wegmans

ergonomics team Ergonomics evaluation of the current

process Eliminate the need to manually lift and

manipulate 50-lb bags of dry ingredients and scaling buckets

Create documentation outlining acceptable work procedures

Implement solutions

Customer Needs: Equipment Equipment for sifting and screening dry

ingredients Research and design the necessary

equipment Improve product quality while maintaining

the current process time and ergonomics Properly document all equipment

specifications and procedures Implement the equipment

Specifications: Area Layout Volume of short-term storage area (ft3) Volume of long-term storage area (ft3) Transport distance from short term

storage to the scaling area (ft) Transport distance from long-term

storage to short-term storage (ft)

Specifications: Process Improvements Process Cycle Time (minutes) Process Steps (count/cycle) Shrink (material loss from process start

to process end in lbs)

Specifications: Ergonomics Manual lifting and manipulating of

scaling buckets per shift Manual lifting and manipulating of

ingredient bags per shift Noise exposure per shift Reported safety incidents and injuries

(count/year translated to $$)

Specifications: Equipment Product quality by defective batches

(count/time) Composed of a non-contaminating

material such as stainless steal or nylon Must follow FDA Regulations Process time (minutes)