1. P09713 – FRESH BREAD AND ROLL SCALING ROOM Customer Needs and Product Specifications Senior Design I: Winter 2008-2009 Cecilia Enestrom, Kate Gleason, Erik Webster, Grant Garbach, Andrew Tsai

2. Customer Needs: Area Layout  Long-term storage area  Short-term storage area  Reduce operator travel distance by combining the short-term storage and scaling locations  Document and implement the improved layout

3. Customer Needs: Process Improvement  Gain a firm understanding of the current process through value stream mapping  Reduce overall process cycle time  Eliminate double handling of materials  Combine the initial and final scaling operation  Determine and reduce current shrink  Determine future state value stream map and inventory management plan based on the improved layout design  Implement a Lean initiative for future improvement

4. Customer Needs: Ergonomics  Work with and assist the existing Wegmans ergonomics team  Ergonomics evaluation of the current process  Eliminate the need to manually lift and manipulate 50-lb bags of dry ingredients and scaling buckets  Create documentation outlining acceptable work procedures  Implement solutions

5. Customer Needs: Equipment  Equipment for sifting and screening dry ingredients  Research and design the necessary equipment  Improve product quality while maintaining the current process time and ergonomics  Properly document all equipment specifications and procedures  Implement the equipment

6. Specifications: Area Layout  Volume of short-term storage area (ft 3 )  Volume of long-term storage area (ft 3 )  Transport distance from short term storage to the scaling area (ft)  Transport distance from long-term storage to short- term storage (ft)

7. Specifications: Process Improvements  Process Cycle Time (minutes)  Process Steps (count/cycle)  Shrink (material loss from process start to process end in lbs)

8. Specifications: Ergonomics  Manual lifting and manipulating of scaling buckets per shift  Manual lifting and manipulating of ingredient bags per shift  Noise exposure per shift  Reported safety incidents and injuries (count/year translated to $$)

9. Specifications: Equipment  Product quality by defective batches (count/time)  Composed of a non-contaminating material such as stainless steal or nylon  Must follow FDA Regulations  Process time (minutes)