1 / 40

Detailed Design Review P10712 Wegmans Cheesecake Process Improvement

Andreana Crance Kevin Rodas Rob Santora Jeremy Smith Matt Syska. Detailed Design Review P10712 Wegmans Cheesecake Process Improvement. Detailed Design Review Discussion Agenda. Bring Wegmans up to date with process improvement findings Review proposals for process improvement

lot
Download Presentation

Detailed Design Review P10712 Wegmans Cheesecake Process Improvement

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. Andreana Crance Kevin Rodas Rob Santora Jeremy Smith Matt Syska Detailed Design Review P10712 Wegmans Cheesecake Process Improvement

  2. Detailed Design Review Discussion Agenda

  3. Bring Wegmans up to date with process improvement findings Review proposals for process improvement Set the stage for MSD II and implementing changes Goals for Detailed Design Review

  4. Customer Needs

  5. Customer Needs

  6. Engineering Specs

  7. process steps and 7 forms of waste

  8. process steps and 7 forms of waste

  9. process steps and 7 forms of waste

  10. Pre & Post Tunnel Oven

  11. Proposal 1: Marble Cheesecake Process Improvements Suggestion: -Relocate marble cheesecake table Current Location: Blue Proposed Location: Red

  12. Implied Results: • Reduced travel time: ~60’ shorter distance round trip, 50% reduction • Time saved when moving trays of batter, when operators travel from mixing area to assist in marble • Operators can see whole process: • Queue build up at marble is visible, operators can adjust to reduce queue • More of a U-Shaped design than current • Reduced strain on operators Proposal 1: Marble Cheesecake Process Improvements

  13. Move the table for 1 shift • Complete time studies • Gather employee opinion • If test successful: • Analyze new process (time studies) • Gather employee opinion for additional improvement • Create standard work • If test unsuccessful: • Gather employee opinion • Why unsuccessful? Can we design out the problems in a different way? • Redesign concept Proposal 1: Test Plan

  14. Proposal 1: Risks

  15. To reduce ergonomic strain of water pouring process and ensure consistent volumetric pouring with controlled and timed flow. Proposal 2: Assisted Water Pouring Unit Pneumatic Power Pro’s: • Air leaks are not dangerous and will not contaminate food • Easier to run air hose than electric line • Air disconnects are easy to use Con’s: • Need to run air line to unit • More parts to maintain, replace • Only one Time State for given setup, must be changed manually • Electric Power • Pro’s: • Digital timer easy to program • Possibility of programming different Time States for Large or Small cake pans • Fewer parts to maintain • Con’s: • Water and electricity don’t mix • Need to run power line to/from unit • or Use batteries • Have to store batteries • Make replacement of batteries easy

  16. Proposal 2: Assisted Water Pouring Unit Cycle Time Comparison between Current and Proposed with AWP Unit * Time to pour with AWP Unit is estimated as approximately the same time it takes to load the pans onto the oven belt 2.08 min. left to work 2.68 min. left to work Time saved=~36 sec. per row ~ 35 rows/shift * 36 sec/row savings = 1260 sec = 21 min. saved at loading process

  17. Mounted to side of oven for ease of use and accessibility. • Trigger release to allow water flow to pans. • Water and power source from adjacent wall is able to disconnect from unit. • Unit is removable from mount to allow cleaning, maintenance and storage when not in use. • Will eliminate ergonomic issues of bending into water bucket and time to refill and wheel over bucket. Proposal 2: Assisted Water Pouring Unit

  18. Inside AWP-Unit Delay Unit Proposal 2: Assisted Water Pouring Unit Actuator/2-Way Water Line Flow Control Water Source Air Source Air Line To Nozzle From triggers To Triggers

  19. Proposal 2: Handheld Unit Design will be dependant on Ease Of Use and Ergo concerns Will be developed during MSD 2 Shown is the basic concept as seen by the team

  20. Proposal 2: Assisted Water Pouring Unit Schematic of Pneumatic and Hydraulic Lines

  21. Proposal 2: Bill of Material Approximate Total: $360.00

  22. Calibrate and optimize in lab • Implement into Wegmans facility under supervision • MSD students will be present during test use at Wegmans • Recalibrate/iterate if necessary Proposal 2 Test/Implementation Plan:

  23. Total price for AWP-Unit: about $360.00 Price for Rail and Carriage to mount: $468.52 (quoted from igus) To avoid extra spending, the Unit will be statically mounted to the Side of the Tunnel Oven with a hose long enough to reach the far end ~15’. To avoid problems with unruly hoses, a cable retractor may be used. For a hose roughly 15’ long, cable retractors to reach $300-$400. To reach mid-hose (8’ retractors) the price is $81. Proposal 2: Cost

  24. Depanning currently a bottleneck for small cheesecake. Oven currently the bottleneck for large cheesecake. Oven release rate: 4m 35s (4.58 min) Proposal 3: Depanning Cycle Time (with current oven capacity)

  25. Proposal 3: Depanning Cycle Time (with current oven capacity) • Depanning currently the bottleneck with small cheesecake. Oven currently the bottleneck with large cheesecake. • Oven release rate: 4m 35s (4.58 min) -> 1 Small Cheesecake every 4.30 seconds (64 per row), 1 Large Cheesecake every 8.60 seconds (32 per row). Small Cheesecake • 2.5 operators depan 64 cheesecake in 8.6 min. (2 depanning, 0.5 helping with bread baskets) -> 8.06 seconds per cheesecake. Large Cheesecake • 3 operators depan 32 cheesecake in 3.6 min (2 depanning, 1 helping with bread baskets) -> 6.75 seconds per cheesecake. On a Typical Run (710 Small, 750 Large) • Small cheesecake are run first, inventory builds up. Once large cheesecakes begin to come out of the oven, operators catch up from large cheesecake 20 minute “freeze” time and the large cheesecake shorter takt time. • Do not catch up completely. -> Still ~30 minutes of depanning to be completed once all cheesecakes have left oven.

  26. Suggestion 1: Depanning Kaizen Event

  27. Proposal 3: Depanning Cycle Time (with current oven capacity) - Risks

  28. Set up & run Kaizen event Implement changes Follow up on success Measure new process Continue to improve! Proposal 3 & Suggestion 1 Test Plan:

  29. Proposal 4: Depanning Cycle Time (with improved oven capacity)

  30. Proposal 4: Depanning Cycle Time (with improved oven capacity) Average Tunnel Oven Capacity • Current rate: Small: 14.0 Cheesecakes/ min • Large: 7.0 Cheesecakes/ min • Small tray plan: Small: 21.0 Cheesecakes/ min (50% increase) • Large: 7.0 Cheesecakes/ min • (0% increase) • Large tray plan: Small: 15.7 Cheesecakes/ min (12.5% increase) • Large: 7.9 Cheesecakes/ min • (12.5% increase)

  31. Proposal 4: Depanning Cycle Time (with improved oven capacity) 16”x 26”x 1.5” Large Pan Design Fits both large and small cheesecakes.

  32. Proposal 4: Depanning Cycle Time (with improved oven capacity) 12”x 26”x 1.5” Small Pan Design Fits small cheesecakes

  33. Proposal 4: Depanning Cycle Time (with improved oven capacity) Pricing • 16”x 26” Large Cheesecake Pan • 1 @ $ 455.23 ea. • 12 @ $ 81.98 ea. • 100 @ $ 48.78 ea. • 300 @ $ 43.70 ea. • 12”x 26” Small Cheesecake Pan • 1 @ $ 453.23 ea. • 12 @ $ 79.98 ea. • 100 @ $ 46.79 ea. • 300 @ $ 41.70 ea. *Quotes via Universal Precision Corp. with an approximate lead time of 6 weeks.

  34. Proposal 4: Depanning Cycle Time (with improved oven capacity) How can we make the new pan idea work? Increase the throughput rate of depanning using a kaizen event and possibly adding second depanning station (2 more employees for approximately 45 minutes).

  35. Proposal 4: Depanning Cycle Time (with improved oven capacity) Current Depanning Method • Small cheesecakes sit waiting for depan for up to 45 minutes • Causes sticking to pan • Total depan time is approximately 3.5 hours With Second Depan Station • Small cheesecakes never sit waiting (current pans) • Small cheesecake pans sit waiting for maximum of 13 minutes (12”x 26” pans) • Sticking reduction • Waste reduction • Total depan time is approximately 2 hours • Allows for mew tray idea (Frees up oven faster)

  36. Implement changes to depanning to ensure it will meet demands of new pans (throughput) Blanket order to ensure that design meets proper specifications (fit, volume, etc) Proposal 4 Test/Implementation Plan:

  37. Proposal 4: Depanning Cycle Time (with improved oven capacity)

  38. Use 5S/Simplification techniques to organize the area(s): • Tape on floor • Dedicated storage • Standard work • Workers assigned to clean Suggestion 2: 5s/Simplification Process

  39. MSD II Preliminary Project Plan

More Related