Wegmans Fresh Bread and Roll Scaling Area

1. Wegmans Fresh Bread and Roll Scaling Area Project Review II Erik Webster Kate Gleason Cecilia Enestrom Grant Garbach Andrew Tsai

2. Project Timeline DMAIC Strategy Define 12/1/2008 – 12/19/2008 Measure 12/15/2008 – 1/16/2009 Analyze 1/16/2009 – 2/20/2009 Improve 2/20/2009 – 4/10/2009 Control 4/10/2009 – 5/15/2008

3. Customer Needs Assessment

5. Ergonomics Background Information • Lifting tasks pose a high risk of injury to the production employees • 4.6% of injuries in the bakeshop can be attributed to the scaling operation • Accounted for 9.6% of the total committed charges resulting from workplace injuries to the Bake Shop in 2008 • Accounted for 21.32% of the total incurred costs resulting form workplace injuries to the Bake Shop in 2008 • The scaling project aims to reduce these costs by eliminating or manipulating lifting tasks that are not ergonomically acceptable

6. Objective and Methodology • Calculate the NIOSH Index for each lifting task • The NIOSH Index provides a guideline to evaluate potential lifting-related injuries that could result from the scaling operation • Index >2.00 poses an increased risk of injury to less capable workers • Index >3.00 poses a risk of injury to all workers

7. Assumptions • Asymmetry angle is zero • The frequency of each task has no effect on the index • The duration of each lifting task has no effect on the index • The coupling for all lifts is “good”

8. Results

9. Results

10. Results

11. Results

13. Ergonomic Specifications

14. New Layout & Process Improvement Customer Needs • Area for short-term storage • Area for long-term storage • Relocate the scaling area into the current short-term storage room • AutoCAD drawing of improved layout • New process flow diagram

15. Bread and Roll Ingredients Total : 114 pallets

16. Bread and Roll Ingredients Total : 69 pallets

17. Long Term Storage • Pallets per Rack: 2 deep, 2 high (3rd row not used for ingredients) = 4 pallets • 69 pallets needed • 69 / 4 = 17.25 = 18 racks needed

18. Proposed Long Term Storage Location

19. Distance: approx. 377.95 ft

20. Forklift Distance • Forklift Truck Speed: • 5 mph (440 feet per minute) • Distance to Long Term Storage: • 4535.4 inches (377.95 feet) • Calculation: • 377.95 / 440 = 0.859 minutes ( ~51.5 seconds)

21. Short Term Storage Area Considerations • New Inventory Management Strategy • How much of each ingredient in short term storage • How ingredients will be stored • How they will be transported from long to short term storage • How often they will be transported from long to short term storage

22. Short Term Storage Area Conclusions: • Ingredients stay stored as pallets • Keep current racking system • Can transport easily with forklifts without any double handling of bags in long term storage area • Minimum storage requirement of 45 pallets in short term storage area • Enough to stock at least 1 pallet of every ingredient and 3 of Stoneground

23. Short Term Storage Area Layout Implications: • Pallets per rack: 2 per row, 2 rows (not using third one) = 4 pallets • 45 pallets needed • 45 / 4 = 11.2 = 12 racks needed

24. Assigned Storage Locations

25. Short Term Ingredient Pallet Locations

26. Restocking Schedule Results • Restocking schedule was created for the first 10 weeks using daily percentage of individual ingredient storage used

27. Process Improvement Results • Restocking will take between 30 and 45 minutes every day • The maximum # of extra pallets due to leveling is 10, so the short term storage must have the capacity to store 55 pallets • Will be stored on third shelf of racks • Moving bin area into short term storage eliminated the need for moving shelves • No more ergonomic concern there

28. Current Scaling Area: approx. 320” x 126”

29. Current Process New Process

30. Process Improvement Major implications: • Restocking must be done before scaling starts at 2pm • No dead time between end of preparation and receiving batch cards • At least 35 minutes of walking time will be eliminated

31. Layout Design & Process Improvement Summary • Long term storage needs 18 racks • Short term storage area meets capacity requirements with bin area relocated into it • 30 to 45 minutes of restocking with a forklift every day before 2pm • Eliminates: • The worker’s walking and handling time by at least 45 minutes • The need for the worker to lift heavy bins to and from high shelves

32. Layout Design & Process Improvement Next Steps • Fitting the equipment into the short term storage area • Determining where the equipment fits into the process • Interfaces between purchasing, forklift operator, and the scaling workers

33. Customer Needs for Sifting and Screening Dry Ingredients I. Determine the appropriate sifting and screening equipment. Improve product quality by reducing contaminants. Maintain or decrease the process time. IV. Maintain or improve process ergonomics.

34. Specifications From Customer The equipment will use the 460 volts power source available at the Wegmans facility. This type of generic power source is the easiest to install in manufacturing facilities. The equipment will fit within a three-pallet size area to minimize the footprint to allow more room for short-term ingredient storage. The equipment will be mobile. This will allow the machine to be more adaptable for changing conditions. The equipment will meet OSHA standard for noise level under 85dB. The equipment should be washable and possible use of compressed air at 90 to 100 psi. The equipment will be able to handle the throughput of dry ingredients including the 5% annual growth rate for the next four years. The equipment will not have parts that will contaminate the product. Can be safely operated by workers without special protection. All parts are stainless steel food grade compatible. Screen size to be mesh 10. NEMA 4X approved electrical box

36. Benchmarking Equipments for Alternate Equipment Selections Option 1: Company: Kemutec Powder Technologies Inc.

 Address: 130 Wharton Road, Bristol PA 19007

 Telephone: (215) 788-8013 Model Number: K300C

37. Benchmarking Equipments for Alternate Equipment Selections Option 2: Company: Rotex Address: 1230 Knowlton Street

 Cincinnati, OH 45223

 Telephone: (513) 541-1236 Model Number: M2120

38. Benchmarking Equipments for Alternate Equipment Selections Option 3: Company: Minox Elcan Address: 325 Waverly Avenue

 Mamaroneck, NY 10543

 Phone: (914) 381-7500

 Fax: (914) 381-8500 Model Number: SXE Round

39. Customer Needs I: Selected Equipment Company: SWECO Sales Rep: Jonathan P. Ansley

 Direct: (585) 330-1754

 Office: (585) 473-7848

 Fax: (585) 473-2971
 Model Number: MX48S88

40. Customer Needs II: Improve Product Quality 8 incidents in the Foreign Material Report were the direct results of pieces of the ingredient bags found in the customer products. 1 incidents in the same report was the result of chipped wood from the pallet found in the customer product. The sifting and screening equipment will reduce foreign materials found in the customer products.

41. Equations Used

42. Calculations

45. Testing at Wegmans

46. Recommendation Sweco 48” Vibro-Energy Separator Model MX48S88 Mesh 4 Screen Size Capable of 8100lbs per hour Assume density 45lbs/ft3