Barilla project
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Barilla Project. Robert Bolster Carly Bormann Nate Guetzko Megan Rudd. Background.

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Barilla Project

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Barilla project

Barilla Project

Robert Bolster

Carly Bormann

Nate Guetzko

Megan Rudd


Background

Background

Barilla America has two manufacturing plants in the United States. Due to being one of two manufacturing plants and therefore suppliers in North America, disruption in production leads to an overall shortage for the company. The manufacturing plant located in Ames, Iowa runs four production lines. Two of these lines run “short pasta” and two lines run “long pasta.” An example of short pasta would be penne and an example of long pasta would be spaghetti.


System

System

Production

Silo

Stripper

Autoloader

Packaging

Packaging packages the pasta and sends it to shipping

The Silo is a large housing of inventory that can hold seven floors of pasta

The Stripper is a machine that cuts the pasta to the appropriate length

The Autoloader is a machine that fills buckets on the bucket conveyer to go to packaging

Pasta is extruded through the necessary shape, then sent through the oven to cook. Cooking time is vital to overall quality


Problem statement

Problem Statement

Line Three is continually having to space out production and stop extruding pasta, or gap the line, in order to avoid the line shutting down due to a bottleneck within the system.  When gapping is employed, the pasta does not cure correctly in the oven at the beginning of the gap and at the end of the gap. This results in poor quality, causing waste in product and waste in production time.


Barilla project

Plan

Through multiple observations of production on different shapes of pasta, as well as data collection on the rate of occurrence of production inconsistencies, numerous bottlenecks were identified. From there, different testing methods were implemented in an attempt to reduce the bottlenecks and keep pasta flowing consistently.


Data collection

Data Collection

In order to collect data, a standardized data collection form was created. The data that was collected regularly was

  • Cutting speed

  • Actual speed

  • Number of times the cutting machine tries cutting a non-existent batch (Phantom)

  • Number of empty buckets

    The reason the number of empty buckets and phantom sticks were taken into account is because this is time lost in production and a contributing factor to the occurrence of production gaps.


Data actual speed of the stripper

Data: Actual Speed of the Stripper


Data recommended stripper settings

Data: Recommended Stripper Settings

The average number of good sticks was calculated per Phantom in order to determine at what set speed the least amount of Phantoms occur.


Data unfilled buckets on bucket conveyor

Data: Unfilled Buckets on Bucket Conveyor


Data cost

Data: Cost

The Table below shows the cost to Barilla for the missed production when buckets are missed.


Data old vs new

Data: Old vs. New


Barilla project

Silo

Production

Silo

Stripper

Autoloader

Packaging


Recommendations silo

Recommendations: Silo

  • Phantoms are caused due to the floor chain stopping when the main chain is still running causing a gap which in turn means a stick does not get picked up

    • Solution

      • The programing within the silo should be examined to ensure that that is not causing the issues

      • Test the sensors to see if they are causing the stop and replace the sensors if necessary

      • Find a way to sync the two speeds to prevent skipping sticks


Autoloader

Autoloader

Production

Silo

Stripper

Autoloader

Packaging


Recommendations autoloader

Recommendations: Autoloader

  • The autoloader should be set at continuous via properly setting the sensors sensitivity.

  • The flap that delegates which side of the autoloader the pasta should flow should be set to the middle

  • Both should be included in the PM reports to ensure the autoloader is properly set at all times


Recommendations bucket conveyor

Recommendations: Bucket Conveyor

  • The sensor that detects whether a bucket is empty or full on the bucket conveyor should be replaced for the laser sensor

  • The sensor should also be mounted on its own structure and not to a vibrating structure like it is currently.

  • If the sensor is not replaced then a standard of work needs to be put in place in order to ensure the sensor is clean otherwise the sensor registers all the buckets as full.


Packaging

Packaging

Production

Silo

Stripper

Autoloader

Packaging


Recommendations packaging

Recommendations: Packaging

Throughout the data collection process there was difficulty collecting the data due to packaging being down. As soon as packaging goes down the autoloader stops as well as the stripper. Even though both of these areas are stopped pasta is still being extruded. This means that once packaging stops inventory is automatically increasing dramatically in production which can cause a shut down. Therefore, the first recommendation is that as soon as packaging has a problem maintenance must be informed and that is first priority.


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