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Frozen Cookies Capacity Increase

Frozen Cookies Capacity Increase. Bridget Eggers, Richard Latham Tyler Brent, Valeria Gonzalez. Presentation Goals. Is the current state of our project well defined? Is the information presented relevant to the project goal? Is there any missing information that you believe would be helpful?

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Frozen Cookies Capacity Increase

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  1. Frozen Cookies Capacity Increase Bridget Eggers, Richard Latham Tyler Brent, Valeria Gonzalez

  2. Presentation Goals Is the current state of our project well defined? Is the information presented relevant to the project goal? Is there any missing information that you believe would be helpful? Feedback and questions are encouraged

  3. Project Scope • Establish synchronized flow between scaling, mixing, dividing and packaging steps in frozen cookie production for optimal productivity. Scaling Stage Mixing Dividing

  4. Defining Current State • Undefined variability in and around the production line • There is a bottleneck between the mixing and dividing steps • Underutilization of resources • Scheduling issues • Use of overtime • Lack of standardization • Production delays

  5. Frozen Cookie Demand 2013

  6. Data Collection

  7. Data Sources • Frozen Bakery Tracking Form- • Actual Packaging Times (Cakes, Muffins, Doughnuts, Frozen Cookies) • APV Commercial Oven Tracking Form • Actual Commercial Oven Times (Commercial Cookies) • Frozen Bakery Tracking Form • Actual Dividing Times (Frozen Cookies) • Weekly production schedules for commercial cookies • Scheduled Commercial Oven Times (Commercial Cookies) • Weekly production schedules for frozen cookies • Scheduled Packaging Times (Cakes, Muffins, Doughnuts, Frozen Cookies) • Frozen Cookie Cycle Times and Recipes • Cookie Capacity & Capability

  8. Seasonal Demand Data Cases

  9. Number of Observations

  10. Analysis

  11. Actual vs. Scheduled Commercial Oven Production Time

  12. Mixing

  13. Mixing Station

  14. Planned vs. Actual Mixing Time

  15. Planned vs. Actual Mixing Time

  16. Dividing

  17. Dividing Station The following timeline shows value-added (colored sections) vs. non-value added (white sections)activities. Each color represents one trough There is not continuous flow within the station

  18. Planned vs. Actual Dividing Time The following graph shows the scheduled vs. the actual time for frozen cookies on the divider

  19. Actual vs. Scheduled Packaging Times

  20. Conclusions • Variability derives from other production lines that are sharing resources • Mixer with Commercial cookies • Blast Freezer with Cakes, Muffins & Doughnuts • Changeover time is not accounted for in scheduling • Planned vs Actual cycle times are not consistent • Labor intensive tasks on Mixer yields high variability in cycle times • Unplanned production adjustments affect scheduled availability of shared resources

  21. Open items & future work Observation on the pre-scaling station Further analysis on commercial line change over times Further analysis on variability in the cake, muffin and doughnut lines Identify most effective and feasible solutions concepts

  22. Q& A

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