Wegmans Fresh Bread and Roll Scaling Area

Phase Review I

Erik Webster

Kate Gleason

Cecilia Enestrom

Grant Garbach

Andrew Tsai

Customer Needs AssessmentCustomer

NeedDescription Comments/Status

1.0 Layout Design for the New Scaling Area  

1.1 Area for short-term storage  

1.2 Area for long-term storage  

1.3 Relocate the scaling area near the short-term storage area  

1.4 AutoCAD drawing of the improved layout  

     

2.0 Sifting and screening dry ingredients  

2.1 Determine the appropriate sifting and screening equipment  

2.2 Improve product quality by reducing contaminants  

2.3 Maintain or decrease the process time  

2.4 Maintain or improve process ergonomics  

     

3.0 Lean Process Improvements  

3.1 Reduce process time  

3.2 Reduce shrink  

3.3 Determine the future inventory management strategy  

3.4 Create necessary SOP documents  

     

4.0 Ergonomics Improvements  

4.1 Reduce the manual lifting of buckets  

4.2 Reduce the manual lifting and manipulating of 50-lb bags  

     

DMAIC Strategy

Define 12/1/2008 – 12/19/2008

Measure 12/15/2008 – 1/16/2009

Analyze 1/16/2009 – 2/20/2009

Improve 2/20/2009 – 4/10/2009

Control 4/10/2009 – 5/15/2008

Project Timeline

Scaling takes place in 2 areas:

Back Scaling Area Bin Area

50 lb bags are taken from the back scaling area while the remainder of what is needed is measured in the bin area.

• Whatever is left over from the 50 lb bagsis measured in the bin area by scoopingout the ingredients from the bins, placingthem in a barrel, and measuring it onthe scale.• There is currently 2 scales in the bin area.

Back Scaling Area

• Bags are removed off the skids manually onto batch carts.

• The 50 lb bags, the liquid barrels, and the mixed dry ingredient barrels are put onto a cart and ready to be moved to mixing.

Opportunities for Improvement

Back Scaling Area Bin Area

Wegmans would like to move the bins to the back scaling area. This may involve the recommendation of getting rid of the bins altogether and implementing another system.

Opportunities for Improvement

• There are pounds of dry ingredient waste on the floor of the bin area.

• Possible causes:– Shape of scoop– Distance from bin to scale– Worker carelessness

• The daily # of repetitions

• No standard long term, short term storage

• Not first in first out

• No clear labeling on where ingredients are located

• Scaling area location leads to unneeded walking (~ 31-39 steps)

Existing Issues

Ingredient Weekly Pallets Used Round Up to Whole Pallets

Peak Pallets Used Round Up to Whole Pallets

Stoneground 10.000 15.000Specialty Stoneground 6.000 8.000Ultra Grain 4.000 6.000Vital Wheat Gluten 4.000 5.000Salt Superior 3.000 4.000Yeast 3.0000 4.0000Breadmate 3.000 4.000DOH Conditn AA 2.000 3.000Watson Honey Bran Base 2.0000 2.0000Gran Sugar 2.000 3.000Watson Lite Wheat Base 2.0000 2.0000EZ Potato Base 2.000 2.000Hearty Bread Base 2.0000 2.0000DM 1.000 2.000Watson Oat Bran Base 1.000 1.000Stay Soft W 1.000 2.000White Rye Flour 1.0000 2.0000NF 1.000 1.00012 Grain Blend 1.000 1.000Dry Dimalt/Non Diastatic 1.000 1.000EZ Kaiser Base 1.000 0.000Non-Fat Dry Pro (Promix) 1.000 1.000

Ingredient Weekly Pallets Used Round Up to Whole Pallets

Peak Pallets Used Round Up to Whole Pallets

Buttermilk Blend 1.000 1.000Watson Lite White Base 1.000 1.000Canadian Oat Base 1.0000 2.0000Med Granulated Sugar 1.0000 1.0000Potato Base (Vandenburgh) 1.000 0.000Brown Sugar 1.0000 2.0000Course Cracked Wheat 1.0000 1.0000Corn Sugar Solids 1.000 1.000Soy Flour 1.0000 1.0000Dry Molasses 1.0000 1.0000Odessa Pump Base 1.00000 1.00000Caravan Rye 12 Base 1.00000 1.00000Omega 3 Powder 1.0000 1.0000EZ Sour 1.0000 1.0000Whole Caraway Seeds 1.000 1.000Ground Caraway 1.0000 1.0000Dry Molasses 1.000 0.000Cinnamon 1.0000 1.0000Seasoning (For seasoned stuffing bread) 0.00000 0.00000Dakota Specialty 0.000 0.000Double Spice 0.000 0.000B&V Flavor 0.000 0.000

Total 72.000 89.000

Usage Rounded Up to Whole Pallet

Daily Ingredient UsageIngredient Daily Pallets Used

(6 days)Daily Pallets Used in Peak times (6 days)

Buttermilk Blend0.076 0.114

Watson Lite White Base 0.075 0.112Canadian Oat Base 0.060 0.219Med Granulated Sugar 0.058 0.081Potato Base (Vandenburgh) 0.048 0.000Brown Sugar 0.037 0.169Course Cracked Wheat 0.037 0.052Corn Sugar Solids 0.036 0.051Soy Flour 0.031 0.042Dry Molasses 0.028 0.038Odessa Pump Base 0.028 0.046Caravan Rye 12 Base 0.017 0.034Omega 3 Powder 0.015 0.020EZ Sour 0.013 0.006Whole Caraway Seeds 0.010 0.014Ground Caraway 0.007 0.010Dry Molasses 0.002 0.000Cinnamon 0.002 0.141Seasoning (For seasoned stuffing bread) 0.000 0.000Dakota Specialty 0.000 0.000Double Spice 0.000 0.000B&V Flavor 0.000 0.000

Total7.726 11.329

Ingredient Daily Pallets Used (6 days)

Daily Pallets Used in Peak times (6 days)

Stoneground 1.647 2.341Specialty Stoneground 0.887 1.316Ultra Grain 0.587 0.881Vital Wheat Gluten 0.532 0.798Salt Superior 0.415 0.615Yeast 0.406 0.604Breadmate 0.348 0.519DOH Conditn AA 0.289 0.436Watson Honey Bran Base 0.255 0.298Gran Sugar 0.225 0.335Watson Lite Wheat Base 0.219 0.273EZ Potato Base 0.208 0.197Hearty Bread Base 0.191 0.310DM 0.147 0.223Watson Oat Bran Base 0.143 0.077Stay Soft W 0.134 0.204White Rye Flour 0.096 0.226NF 0.091 0.13712 Grain Blend 0.088 0.127Dry Dimalt/Non Diastatic 0.080 0.129EZ Kaiser Base 0.079 0.000Non-Fat Dry Pro (Promix) 0.079 0.133

Incoming PalletsScaling Area

Storage

•Lack of Labeling

What ingredient is it?

Improvements

• Create a long and short term storage• Standardize amount of ingredients in

storage areas• Standardize location of ingredients in

storage area• Place scaling area in the short term

storage area

Ergonomic Analysis

Summarized Injury Data for 2008• 4.6% of the reported injuries in 2008 in the Bake Shop

can be attributed to the scaling operation.• 9.6% of the total committed charges to the Bake Shop in

2008 can be attributed to the scaling operation. The committed charge is the amount charged to the Bake Shop by the Wegmans Risk Management Department. This is the amount that actually comes out of the Bake Shop’s worker compensation budget.

• 21.32 % of the incurred costs in 2008 from the Bake Shop can be attributed to the scaling operation. This is the amount of money in medical bills that the injury has cost Wegmans.

Equipment Specification and Preliminary Design Options

• Mobility of weighting station• Floor layout, potential spacing for new equipments• Screen size and testing• Silo layout plan• Potential sift and screen equipments

Mobility of weighting station

• Make: TORREY• Model 1:  EQM-200/400

W• Model 2:  EQM-W

400/800• The battery pack will last

one shift. • Operator need to plug it

in to recharge.

Floor Layout and Potential Spacing

• No immediate spacing next to the 2 mixers

• No immediate spacing in the current scaling area

• Will determine equipment size based on ingredient usage

Screen Size and Testing

• Stone ground wheat will require screen size 10 or less

• Flour already utilize the silos and passes through screen size 30

• Screen size 10 can be used for all other ingredients

New Silo Layout

• Obtain the new silo layout plan• One of the two new silo will be used for stone ground

wheat • Currently it takes 8 operators approximately an hour

to load the stone ground wheat into the mixer. The silo will help streamline the process as well as screen the ingredient.

48” Round Sweco Separator

• 304 Stainless Steel

• Non-marking caster wheels

• Continuous Ground welds

• Fully washable

• $17,300

Separator

• Large enough for two bags

• Dump into scale bins

• Size 10 mesh– Easy change screens

Safer, Stronger, Cleaner

• Stable base

• Stronger construction

• No painted surfaces

• Minimal aggressive vibration

Dust collection system

• Reduce dust clouds

• Eliminates breathing small particles

• Reduced cleanup

• $6,500