R09710 - Modern Food Processing and Bakery Technology for Lean Production Systems

1. R09710 - Modern Food Processing and Bakery Technology for Lean Production Systems P09713 – Bread and Roll Scaling Room Sponsored by Wegmans Kate Gleason Cecilia Enestrom Erik Webster

2. 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.

3. 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

4. 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

5. Project Improvement Process

6. P09713 Bread and Roll Scaling Room Layout and Process Improvement

7. Bread and Roll Scaling Room Layout and Process Improvement Project Name Bread and Roll Scaling Room Layout and Process Improvement Project Number P09713 Roadmap R09710- Modern Food Processing and Bakery Technology for Lean Production Systems Start Term 2008-2 End Term 2008-3 Faculty Guide Professor Kaemmerlen (Industrial and Systems Engineering Department) Primary Customer Wegmans Facility and Employees Scott Young Chris Isaacson

8. 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

9. Current Scaling Room

10. Scale and Bucket

11. Final Scaling Area

12. New Scaling Area

13. Bread and Roll Scaling Room Layout and Process Improvement Mission Statement • Document 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.

14. Bread and Roll Scaling Room Layout and Process Improvement Key Business Goals/Project Deliverables • Document all current processes and work practices • Develop alternative processes for scaling the dry ingredients • Reduce/eliminate redundancies and double handling in the process • Develop a process for sifting and screening the dry ingredients • Develop the layout for the new scaling area • Identify other opportunities for improvement in the scaling area

15. Bread and Roll Scaling Room Layout and Process Improvement Assumptions and Constraints • Resources for designing solutions and equipment are limited but available. • Budget will be constrained based on decisions made by Wegmans • Wegmans’ engineering resources are limited but available • Space 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

16. Bread and Roll Scaling Room Layout and Process Improvement Preliminary Customer Needs • Relocate and redesign the layout for the scaling area near the bread and roll line • Improve the safety and ergonomics of the process • Develop a process for sifting and screening dry ingredients • Eliminate double handling of dry ingredients • Document and standardize process procedures • Identify and implement Lean process improvements

17. Bread and Roll Scaling Room Layout and Process Improvement Preliminary Risk Assessment • Cost/Budget • Insufficient funds to design and implement solutions for sifting and screening • Customer Approval • Wegmans does not approve of the solutions developed by the project team • Space Restrictions • The area reserved for the new scaling area will not support the process that is developed by the project team

18. Bread and Roll Scaling Room Layout and Process Improvement Staffing Requirements

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

20. Questions?