Detailed design review

1. Detailed design review TYLER BRENT BRIDGET EGGERS VALERIA GONZALEZ RICHARD LATHAM

2. Presentation objectives • Project update • Decide on process improvement activities for Senior Design II • Our goal is to obtain approval for all of the proposed activities and for you to suggest additional solutions • Please ask questions about our proposed solutions to minimize future risks

3. Frozen cookie production Increase Pre Scale Paper Cut Divide Stage Mix Blast Freeze X-Ray Metal Detect Package Close box Freezer to Ship

4. A DAY IN THE PROCESS Frozen Cookies Commercial Cookies

5. Problem Definition Current state • High variability in and around the production line • There is a bottleneck at mixing • Underutilization of resources • Staffing issues • Need for overtime • Lack of standardization • Production delays Target state • Establish synchronized flow between scaling, mixing, dividing, and packaging steps • Increase production capacity • Maximize resources utilization • Reduce/Eliminate the need for overtime • Implement standardized work • Establish schedule flexibility • Track and sustain production system

6. Project status • Started with customer needs and engineering requirements • Observed and collected data • Brainstormed on possible solutions/concepts based on collected data • Created kaizen activities which include feasible concepts • Prioritized and grouped kaizen activities • Created detailed description of kaizen events • Prove feasibility and practicality of these concepts • Assess and refine solutions • Recommend solutions to customer Senior Design II

7. Customer needs & Eng. Requirements

8. Concept selection

9. Process Improvement priority matrix

10. SCALING Process current state • Shares station w/ commercial. • Cross-training evident. • 4 AM – Commercial Pre-Scaler comes in. • 11 AM – Frozen Mixer comes in. • Multiple batches are pre-scaled at a time. • Ingredients are stored in multiple locations. • Work in process is not traceable.

11. SCALING Process IMPROVEMENT

12. Add labels to pre-scaled ingredients

13. SCALING Process IMPROVEMENT

14. Reduce defects on scaling Cookie Pucks no Nuts

15. SCALING Process IMPROVEMENT

16. Checklist of whether ingredients are there before starting a batch

17. MIXING PROCESS CURRENT STATE • Shares with commercial. • Deviation between types. • Average cleaning time: 12 minutes • Labor driven process • Actual vs. Scheduled average process time:

18. Value added vs. non value added

19. Breakdown of mixing process time

20. MIXING PREP ACTIVITIES KAIZEN

21. MIXING PREP ACTIVITIES KAIZEN

22. MIXING PREP ACTIVITIES KAIZEN

23. MIXING CLEAN UP KAIZEN

24. DIVIDING process current state • Shared with doughnuts, muffins, etc. • Average actual run time: 2 hrs and 33 mins • Start time: Min 5:49 pm Max 8:14 pm Avg 6:52 pm

25. Average downtime:

27. DIVIDING PROCESS KAIZEN

28. System level approach Frozen Cookies Commercial Cookies

29. Operations management

30. LABOR MANAGEMENT Improvement

31. Waste reduction through standard work

32. Risk analysis • Brainstormed 27 possible risks for this project, assessed the likelihood of happening, the impact to the project, and ranked them by importance level. • 8 more risks became critical since the beginning of the project

33. Project management tools

34. Discussion