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Summer 2007 Internship Schwan’s Pizza Plant Salina, KS

Summer 2007 Internship Schwan’s Pizza Plant Salina, KS. Presentation Outline. Background Projects Air Leak Audit Hand Washing Sink Audit Water Trough Audit Statistical Process Control Reflection. Andrew Sellers. Born in Salina B.S. – Industrial Engineering at KSU Grad Date: Dec. 2005

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Summer 2007 Internship Schwan’s Pizza Plant Salina, KS

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  1. Summer 2007 InternshipSchwan’s Pizza PlantSalina, KS

  2. Presentation Outline • Background • Projects • Air Leak Audit • Hand Washing Sink Audit • Water Trough Audit • Statistical Process Control • Reflection

  3. Andrew Sellers • Born in Salina • B.S. – Industrial Engineering at KSU • Grad Date: Dec. 2005 • Master’s – Business Admin. at KSU • Expected Grad. Date: May 2008 • Pollution Prevention Institute Intern • Career Interests • Finance • Alternative Energy

  4. Energy Reduction Projects • Air Leak Audit • Hand Washing Sink Audit • Water Trough Audit • Statistical Process Control – Analysis of Topping Weights

  5. Air Leak Audit • Identified 46 leaks costing Schwan’s $23,000+ in electricity • Common locations: • Water Traps • Air Hoses • Air Hose Nozzles • Created maintenance notifications to repair leaks • Created Air Leak Audit Procedure for future audits • Predictive Maintenance order will come up every 6 months in SAP

  6. Water Audit – Information Gathered • Created map of all sinks in the plant • Flow Rates – Continuously Running Water • Flow Rates - Water Troughs • Costs associated with wasted water

  7. Water Project Assumptions • Water Cost – $1.97 per CCF • Natural Gas Cost - $7.00 per DTH • Assumed incoming temp was 50oF • Assumed boiler operates @ 60% efficiency • WWTP Cost – $2.97 per 1000 gallons • Conservative estimate without Fixed Costs • Assumed 20% usage of hand washing sinks

  8. Continuously Running Water

  9. Hand Washing Sink Audit • 53 sinks in plant • 36 had continuously running water • Why? - To keep water at 100oF • Average Annual Cost: • Water/sink: $373.89 • Energy/sink: $788.25 • WWTP/sink: $421.66 • Average Total Cost of Continuously Running Water per sink: $1,583.80

  10. Alternatives • Grundfos Comfort System • Installed on sample sink • Could not guarantee 100oF • Could not overcome any pressure difference • Stiebel Eltron Tempra 20 • Instantaneous Electric Water Heater • Minimum Water Flow is 2.2 GPM • Can Handle 60oF Temperature Rise at 2.2 GPM • Cold Water In, 100+oF Out

  11. Tempra 20 Costs vs. Savings – Per Sink • Initial Costs $2,500 • Unit: $720 • Installation: $780 • Electrical: $1,000 • Annual Savings $654 • Water $374 • Energy $788 • WWTP $422 • Electric vs. Gas ($930)

  12. Instantaneous Water Heater Cash Flows Cost of Capital: 12% Payback Period: 3 years 9.9 months NPV (5 years only): -143 Recommended

  13. Water Trough @ West Entrance

  14. Water Trough Study • Performed time study for 30 minutes @ West Entrance – North Trough • 59 gallons were wasted • Assume same waste every 30 minutes for 18 hours a day… • Water Cost: $2,054 • Energy Cost: $4,351 • WWTP Cost: $2,316 • Total Cost: $8,721

  15. Recommendations • Remove water troughs at West Entrance and replace each with freestanding sinks • Superior Plumbing quotes: • 4 sinks: $5,800 • 8 sinks: $11,300 • Payback Period < 1 year Recommended

  16. Blast 2 Canadian Bacon Veggies Pepperoni Mushroom Sausage Blast 7 Cheese Pepperoni Sauce Blast 3 Line 1 Cheese Line 2 Cheese Statistical Process Control

  17. Method • Collect Data • Measure topping weights on all lines • 5 Trays at a time • Collect 40 samples (Blast 7 – 20 samples) • Analyze Data • Minitab • Control Charts • Normality Tests • Process Capability

  18. What We Found • Machines are not applying toppings evenly – Need to balance! • Excess Toppings totaling $276,000/year • $200,000 from Blast 3 Line 1 Cheese • Quality Issues • Under applying toppings amounts to $365,000/year • Cuts costs, but could lead to unsatisfied customers

  19. Blast 2 - Veggies

  20. Blast 2 – Canadian Bacon

  21. Blast 2 - Mushroom

  22. Blast 3 – Line 1 Cheese Mean = Target Mean >> Target

  23. Blast 3 – Line 2 Cheese Mean = Target Mean < Target

  24. Recommendations - SPC • Continue to collect topping data – it is extremely useful in locating sources of waste • Standardize measuring trays – We noticed a ¼” difference in diameter of trays being used for the same pizza size • Make machine adjustments to balance lines – Could save lots of $$$

  25. Summary of Energy Reduction Projects

  26. Reflection • What I have learned • Network • Determine who to turn to for questions ASAP within Schwan’s and outside of Schwan’s • Communication • Learning to be assertive • Project Management • Manage time to ensure completion of projects • Information Gathering • Takes time, but necessary to justify projects

  27. Acknowledgements • People who have provided me with valuable info: • Jon Robertson • Chris Sharpe • Jay Reimer • Chris Harapat (Superior Plumbing) • Randy Simmons • Cathy Raymer • Garry Waldren • Chuck Thornberg • Brian Beier • Phillip Richardson • Bryan Downie

  28. Questions?

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