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Seasonal Application o f MSW/PSW

Seasonal Application o f MSW/PSW. Ralcorp Frozen Bakery Products. Ogden, UT. Introduction to the Business. Seasonal Calendar. Ogden, UT. Size of property = 9 acres Main plant constructed in 1940’s (leased ). Produces packaged frozen cookies and waffles 12 finished production lines

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Seasonal Application o f MSW/PSW

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  1. Seasonal Application of MSW/PSW Ralcorp Frozen Bakery Products

  2. Ogden, UT Introduction to the Business

  3. Seasonal Calendar

  4. Ogden, UT • Size of property = 9 acres • Main plant constructed in 1940’s (leased) • Produces packaged frozen cookies and waffles • 12 finished production lines • 2-3 frosted sugar cookie lines • 4 rotary cut cookie lines • 2 wire cut cookie lines (Meincke) • 1 no-bake cookie line • 1 assembly line • 2 waffle lines: • 700+ SKUs • Theoretical capacity utilization Cookies = 62% (annualized) • Theoretical capacity utilization Griddle = 99%

  5. Ogden, UT – Basic Layout

  6. Ogden, UT Line 1 - Ogden Mixer Extruder Oven Enrobe Cooling Tunnel Cell 1 Package/Palletize Cell 2 Cell 3 • Unique Features: • Tri-Ex Process • Enrobing Products:

  7. Ogden, UT Mixer Extruder Oven Enrobe Cooling Tunnel Cell 1 Package/Palletize Cell 2 Cell 3 Line 2 - Ogden • Unique Features: • Enrobing Products:

  8. Ogden, UT – Lines 1&2 Capacity

  9. Ogden, UT – Lines 1&2 Capacity

  10. Ogden, UT Pre Scale FR. MIX Mixer Extruder Oven Frosting Cooling Tunnel Package/Palletize Cell 1 Cell 2 Cell 3 Cell 4 Line 5 - Ogden • Unique Features: • Auto Tray Packer • Auto Palletizing Products:

  11. Ogden, UT Pre Scale FR. MIX Mixer Extruder Oven Frosting Cooling Tunnel Package/Palletize Cell 1 Cell 2 Cell 3 Cell 4 Line 6 - Ogden • Unique Features: • Wire-cut FSC’s • Auto Palletizing Products:

  12. Ogden, UT Line 8 - Ogden Mixer Extruder Oven Frosting Cooling Tunnel Cell 1 Package/Palletize Cell 2 Cell 3 Cell 4 • Unique Features: • Wire-cut FSC’s • Rotaries • Trays Products:

  13. Ogden, UT – Lines 5,6,&8 Capacity

  14. Ogden, UT – Lines 5,6,&8 Capacity

  15. Prior Process Prior Process for MRP

  16. Prior Process • Excel-based, only using QAD as an input • Macro / VB driven • Many customized reports • Maintained by one individual • Burden to their system/network

  17. Prior Process – Seasonal Tracker

  18. Prior Process – Detailed Schedule

  19. Prior Process – Component Sched

  20. Prior Process – WO Reconciling

  21. Why transition? Why Transition?

  22. Why transition? • Excel process not supported • Cannot be upgraded easily • Corporate IT support near impossible • “Custom” to the plant and scheduler • Standard of work • Community of users • Training available • Support within the company • Maintain QAD – value added • More efficient • Workbench supported by IT, QAD • Regular patches and updates released • Less burden on the planners and systems

  23. Project Charter

  24. MSW/PSW versus Outside Vendor

  25. Ogden MRP Timeline

  26. Risks

  27. Custom Reports Custom Reports

  28. From this…

  29. To this.

  30. From this…

  31. To this.

  32. End result…

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