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Wegmans Fresh Bread and Roll Scaling Area. Phase Review I. Erik Webster Kate Gleason Cecilia Enestrom Grant Garbach Andrew Tsai. Customer Needs Assessment. 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

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Wegmans fresh bread and roll scaling area

Wegmans Fresh Bread and Roll Scaling Area

Phase Review I

Erik Webster

Kate Gleason

Cecilia Enestrom

Grant Garbach

Andrew Tsai



Project timeline
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


Scaling takes place in 2 areas
Scaling takes place in 2 areas:

Back Scaling Area Bin Area

50 lb bags are taken from the back scaling area while the remainder of what is needed is measured in the bin area.


  • Whatever is left over from the 50 lb bags

  • is measured in the bin area by scooping

  • out the ingredients from the bins, placing

  • them in a barrel, and measuring it on

  • the scale.

  • There is currently 2 scales in the bin area.


Back scaling area
Back Scaling Area

Bags are removed off the skids manually onto batch carts.


The 50 lb bags, the liquid barrels, and the mixed dry ingredient barrels are put onto a cart and ready to be moved to mixing.


Opportunities for improvement
Opportunities for Improvement ingredient barrels are put onto a cart and ready to be moved to mixing.

Back Scaling Area Bin Area

Wegmans would like to move the bins to the back scaling area. This may involve the recommendation of getting rid of the bins altogether and implementing another system.


Opportunities for improvement1
Opportunities for Improvement ingredient barrels are put onto a cart and ready to be moved to mixing.

There are pounds of dry ingredient waste on the floor of the bin area.

Possible causes:

Shape of scoop

Distance from bin to scale

Worker carelessness

The daily # of repetitions


Existing issues

No standard long term, short term storage ingredient barrels are put onto a cart and ready to be moved to mixing.

Not first in first out

No clear labeling on where ingredients are located

Scaling area location leads to unneeded walking (~ 31-39 steps)

Existing Issues


Usage Rounded Up to Whole Pallet ingredient barrels are put onto a cart and ready to be moved to mixing.


Daily ingredient usage
Daily Ingredient Usage ingredient barrels are put onto a cart and ready to be moved to mixing.


Incoming Pallets ingredient barrels are put onto a cart and ready to be moved to mixing.

Scaling Area

Storage


Lack of Labeling ingredient barrels are put onto a cart and ready to be moved to mixing.

What ingredient is it?


Improvements
Improvements ingredient barrels are put onto a cart and ready to be moved to mixing.

Create a long and short term storage

Standardize amount of ingredients in storage areas

Standardize location of ingredients in storage area

Place scaling area in the short term storage area


Ergonomic analysis
Ergonomic Analysis ingredient barrels are put onto a cart and ready to be moved to mixing.

Summarized Injury Data for 2008

  • 4.6% of the reported injuries in 2008 in the Bake Shop can be attributed to the scaling operation.

  • 9.6% of the total committed charges to the Bake Shop in 2008 can be attributed to the scaling operation. The committed charge is the amount charged to the Bake Shop by the Wegmans Risk Management Department. This is the amount that actually comes out of the Bake Shop’s worker compensation budget.

  • 21.32 % of the incurred costs in 2008 from the Bake Shop can be attributed to the scaling operation. This is the amount of money in medical bills that the injury has cost Wegmans.


Equipment specification and preliminary design options
Equipment Specification and Preliminary Design Options ingredient barrels are put onto a cart and ready to be moved to mixing.

Mobility of weighting station

Floor layout, potential spacing for new equipments

Screen size and testing

Silo layout plan

Potential sift and screen equipments


Mobility of weighting station
Mobility of weighting station ingredient barrels are put onto a cart and ready to be moved to mixing.

Make: TORREY

Model 1:  EQM-200/400 W

Model 2:  EQM-W 400/800

The battery pack will last one shift.

Operator need to plug it in to recharge.


Floor layout and potential spacing
Floor Layout and Potential Spacing ingredient barrels are put onto a cart and ready to be moved to mixing.

No immediate spacing next to the 2 mixers

No immediate spacing in the current scaling area

Will determine equipment size based on ingredient usage


Screen size and testing
Screen Size and Testing ingredient barrels are put onto a cart and ready to be moved to mixing.

Stone ground wheat will require screen size 10 or less

Flour already utilize the silos and passes through screen size 30

Screen size 10 can be used for all other ingredients


New silo layout
New Silo Layout ingredient barrels are put onto a cart and ready to be moved to mixing.

Obtain the new silo layout plan

One of the two new silo will be used for stone ground wheat

Currently it takes 8 operators approximately an hour to load the stone ground wheat into the mixer. The silo will help streamline the process as well as screen the ingredient.


48 round sweco separator
48” Round Sweco Separator ingredient barrels are put onto a cart and ready to be moved to mixing.

304 Stainless Steel

Non-marking caster wheels

Continuous Ground welds

Fully washable

$17,300


Separator
Separator ingredient barrels are put onto a cart and ready to be moved to mixing.

Large enough for two bags

Dump into scale bins

Size 10 mesh

Easy change screens


Safer stronger cleaner
Safer, Stronger, Cleaner ingredient barrels are put onto a cart and ready to be moved to mixing.

Stable base

Stronger construction

No painted surfaces

Minimal aggressive vibration


Dust collection system
Dust collection system ingredient barrels are put onto a cart and ready to be moved to mixing.

Reduce dust clouds

Eliminates breathing small particles

Reduced cleanup

$6,500


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