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Improvement Plan updates po. Richard Latham Bridget Eggers Tyler Brent Valeria Gonzalez. Presentation Objectives. Summarize what was achieved last semester Present project timeline Updates on activities Mixing Prep Activities Mixing Clean Up Kaizen Scaling Process Improvement

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improvement plan updates po

Improvement Plan updatespo

Richard Latham

Bridget Eggers

Tyler Brent

Valeria Gonzalez

presentation objectives
Presentation Objectives
  • Summarize what was achieved last semester
  • Present project timeline
  • Updates on activities
    • Mixing Prep Activities
    • Mixing Clean Up Kaizen
    • Scaling Process Improvement
    • Operations Management
    • Standard Work Implementation
mixer worker justification project
Mixer Worker justification project
  • Objective:

To make a decision about whether a second operator is justifiable in the frozen cookie mixer process (for cookies with inclusions).

  • Engineering Requirements:
    • Characterization of all process steps
    • Throughput
    • Implemented solutions are consistent across all crews and shifts
    • Tools that make system run smoothly
    • Management approval
  • Test Method:
    • Cycle time improvement
mixer worker justification project1
Mixer Worker justification project
  • Current Progress:
    • Videos taken for Dads, Ultimate w/ nuts, Sub Shop w/ nuts
    • Process analysis completed for one operator
    • Job elements created for two workers based off reasonable assumptions
    • Job element comparison charts created for one worker vs two workers
mixer worker justification project2
Mixer Worker justification project
  • Next Steps:
    • Experiment with two workers
    • Create standard job element sheet for two workers using operator feedback
    • Present findings to management
sanitation kaizen
Sanitation kaizen
  • Objective:

Create a system that allows the sanitation employee to be at the mixer at the right time.

  • Engineering Requirements:
    • No food safety, ergonomics, quality impacts
    • Throughput
    • Characterization of all process steps
    • Implemented solutions are consistent across crews and shifts
    • Tools that make system run smoothly
    • Management approval
  • Test Method:
    • Mixer wait time per week (see Mixer Operator Time Sheet)
sanitation kaizen1
Sanitation kaizen
  • Current Progress:
    • Interviewed Jim Roode about sanitation processes
      • Agreed that sanitation can work on a schedule
      • Suggested ideal state would be a one to two hour notice
      • Sanitation employee will fill out sanitation section of the Mixer Operator Time Sheet
  • Next Steps:
    • Map information flow scenarios for mixer sanitation
    • Collect data on sanitation cycle time
    • Update schedule to include sanitation
    • Present findings to management
recipe modification project
Recipe modification project
  • Objective:

Increase usability of recipe by removing the need for calculations to find the number of bags/boxes needed.

  • Engineering Requirements:
    • Characterization of all process steps
    • Implemented solutions are consistent across crews and shifts
    • Tools that make system run smoothly
    • Sustainable solution methods
    • Management approval
  • Test Method:
    • Does the sheets make sense to the operator? - Yes/No
    • Are the sheets being utilized regularly? - Weekly Team Leader Audit
operations management mixing
Operations Management Mixing
  • Objective:

Make mixer its own resource and develop a single daily mixer schedule.

  • Engineering Requirements:
    • Characterization of all process steps
    • Tools that make system run smoothly
    • Implemented solutions are consistent across crews and shifts
    • Management approval
  • Test Method:
    • Planned vs Actual number of batches (see Mixer Operator Time Sheet)
operations management mixer
Operations Management Mixer
  • Current Progress:
    • Collecting mixer cycle times for frozen and commercial cookies
    • Created preliminary mixing schedule
      • Down time, reason, sanitation
    • Trained mixer operators on mixer tracking sheet
  • Next Steps:
    • Collaborate with frozen and commercial schedulers on mixer schedule
    • Test and validate schedule
operations management divider
Operations Management Divider
  • Objective:

Create changeover matrix for divider for use in scheduling.

  • Engineering Requirements:
    • Characterization of all process steps
    • Tools that make system run smoothly
    • Implemented solutions are consistent across crews and shifts
    • Management approval
  • Test Method:
    • Was changeover time accounted for in the weekly schedule? – Yes/ No
    • Does the matrix clearly provide the changeover time between different cookie types? - Yes/No
operations management divider1
Operations Management Divider
  • Current Progress:
    • Collect reasons for changeover
  • Next Steps:
    • Collect times for changeover
    • Create changeover matrix
    • Present matrix to scheduler
standard work implementation
Standard Work Implementation
  • Objective:

Create work instructions for revised process improvements

  • Engineering Requirements:
    • Characterization of all process steps
    • Implemented solutions are consistent across crews and shifts
    • Tools that make system run smoothly
    • Sustainable solution methods
    • Management approval
  • Test Method:
    • Do the updated work instructions make sense to the worker? – Yes/No
    • Are they being utilized regularly? – Weekly Team Leader Audit
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