Fresh Bread and Roll Scaling Room

1. Fresh Bread and Roll Scaling Room Erik Webster, Cecilia Enestrom, Kate Gleason, Grant Garbach, Andrew Tsai March 20th, 2009

2. Agenda • Project Timeline • Business Objectives • Cost Implications • New Layout and Process • Ergonomic Analysis • Sifting and Screening Machinery • Cost Summary • Improve and Control Plans

3. Project Timeline Six Sigma DMAIC Strategy • Start 12/01/2008 • Define 3 Weeks • Measure 5 Weeks • Analyze 6 Weeks • Improve 8 Weeks • Control 3 Weeks • End 5/15/2009

4. Business Objectives • Reduce labor costs • Scaling worker’s shift is 10-12 hrs • Target shift time is 8 hrs • Reduce costs due to injury during scaling processes • Perform ergonomic analysis • Reduce hazardous heavy lifting • Reduce foreign material in dry ingredients • Implement best practice • Implement sifting/screening equipment

5. Business Objectives • Reduce labor costs • Scaling worker’s shift is 10-12 hrs • Target shift time is 8 hrs • Reduce costs due to injury during scaling processes • Perform ergonomic analysis • Reduce hazardous heavy lifting • Reduce foreign material in dry ingredients • Implement best practice • Implement sifting/screening equipment

6. Current Layout and Process Scaling Worker Shift Starts at 12pm Ends at 10pm-12am

7. Projected Layout and Process Scaling Worker Shift Starts at 2pm Ends at 10 – 11pm

8. Cost Implications • Bin Area moved to Short Term Storage Area • Less walking time • 10-12 hr shift 8-9 hr shift • Labor Savings of 20-40% for scaling worker

9. Business Objectives • Reduce labor costs • Scaling worker’s shift is 10-12 hrs • Target shift time is 8 hrs • Reduce costs due to injury during scaling processes • Perform ergonomic analysis • Reduce hazardous heavy lifting • Reduce foreign material in dry ingredients • Implement best practice • Implement sifting/screening equipment

10. Ergonomic Process Implications • 21.32% of the incurred costs due to injuries within the facility for 2008 can be attributed to the scaling operation. • This translates to approximately $70,000 • Our ergonomic analysis has identified which lifting tasks are hazardous. • Lifting heavy buckets and ingredient bags over head • Assuming many of these injuries can be attributed to hazardous heavy lifting tasks, the cost of injuries due to the scaling process will decrease as a result of our implemented standard work • Estimated 5-16% of the total incurred costs to the Bakery • Translates to approximately $17,500-$52,500

12. Business Objectives • Reduce labor costs • Scaling worker’s shift is 10-12 hrs • Target shift time is 8 hrs • Reduce costs due to injury during scaling processes • Perform ergonomic analysis • Eliminate hazardous heavy lifting • Reduce foreign material in dry ingredients • Implement best practice • Implement sifting/screening equipment

13. Sifting & Screening Equipment Company: SWECO Cost: $19,000

14. Cost Summary • Process Improvement • Cost to move equipment and material • 20-40% labor savings for scaling worker • Ergonomics • Cost of training to alter procedures • 5-16% savings in costs due to injury within the facility, $17,500-$52,500 • Sifting & Screening Equipment • Cost $19,000 • Reduce foreign materials in the product

15. Improve and Control Plans • Shift time savings • Layout of Bin Area • Layout of Short Term Storage Area • Design Short Term Storage Replenishment System • Implementation planning for the sifting and screening equipment • Consider time and labor requirements

16. Questions?