Wegmans Fresh Bread and Roll Scaling Area Phase Review I Erik Webster Kate Gleason Cecilia Enestrom Grant Garbach Andrew Tsai
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: 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 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 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 Improvement 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
No standard long term, short term storage 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
Incoming Pallets Scaling Area Storage
Lack of Labeling What ingredient is it?
Improvements 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 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 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 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 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 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 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 304 Stainless Steel Non-marking caster wheels Continuous Ground welds Fully washable $17,300
Separator Large enough for two bags Dump into scale bins Size 10 mesh Easy change screens
Safer, Stronger, Cleaner Stable base Stronger construction No painted surfaces Minimal aggressive vibration
Dust collection system Reduce dust clouds Eliminates breathing small particles Reduced cleanup $6,500