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P10712 Cheesecake Process Improvement

P10712 Cheesecake Process Improvement. Andreana Crance , Kevin Rodas , Rob Santora , Jeremy Smith, Matt Syska. Meeting Agenda. P10712 Cheesecake Process Improvement.

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P10712 Cheesecake Process Improvement

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  1. P10712Cheesecake Process Improvement AndreanaCrance, Kevin Rodas, Rob Santora, Jeremy Smith, Matt Syska

  2. Meeting Agenda

  3. 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

  4. 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

  5. System Overview

  6. Value Stream Map

  7. Customer Needs & Engineering Metrics

  8. Customer Needs & Engineering Metrics

  9. Customer Needs & Engineering Metrics

  10. Customer Needs & Engineering Metrics

  11. Risks and Contingencies

  12. Risks and Contingencies

  13. Risks and Contingencies

  14. Process Evaluation

  15. What we have observed in Greasing: • Pre process clean up • Sprayer Calibration • Human bending

  16. 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)

  17. Pre-Tunnel • Cluttered area • Human bending • Labor intensive

  18. Post-Tunnel • Cluttered area • Manual process • No standards

  19. 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

  20. Packaging • No dedicated labor • Reaching and bending • Lack of organization

  21. 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

  22. Concept Selection • Discussion

  23. Target Specifications – Marginal and Target Values

  24. 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

  25. 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

  26. 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

  27. MSDI Plan – Our steps forward

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