1. P09713 – FRESH BREAD AND ROLL SCALING ROOM Week 3 Presentation Senior Design I: Winter 2008-2009 Cecilia Enestrom, Kate Gleason, Erik Webster, Grant Garbach, Andrew Tsai

2. Project Timeline  Define: Week 1 – Week 3  Project Scope  Team Roles  Work Breakdown Structure  Customer Needs Assessment  Measure: Week 3 – Week 5  Data Collection Plan  Baseline Data Collection  Project Specifications  Data Organization

3. Project Timeline (continued)  Analyze: Week 5 – Week 10  Perform the data analysis necessary to fully understand the process and make recommendations for improvement.  Improve: Senior Design II  Prepare formal recommendations and justifications for the necessary process improvements.  Control: Senior Design II  Re-evaluate the process following implementation by Wegmans.

4. Customer Needs Revisited Customer NeedDescription 1.0Layout Design for the New Scaling Area 1.1 Area for short-term storage 1.2 Area for long-term storage 1.3 Relocate the scaling area near the short-term storage area 1.4 AutoCAD drawing of the improved layout 2.0Sifting and screening dry ingredients 2.1 Obtain the appropriate sifting and screening equipment 2.2 Improve product quality by reducing contaminants 2.3 Maintain or decrease the process time 2.4 Maintain or improve process ergonomics 3.0Lean Process Improvements 3.1 Reduce process time 3.2 Reduce shrink 3.3 Determine the future inventory management strategy 3.4 Create necessary SOP documents 4.0Ergonomics Improvements 4.1 Eliminate the need to manually lift buckets 4.2 Eliminate the need to manually lift and manipulate 50-lb bags

5. Specifications Revisited Engr. Spec. # Source: Customer Need Specification (description) Unit of Measure Marginal Value Ideal Value 1.0 Layout Specifications 1.1 Volume of long-term storage areaft 3 1.2 Volume of short-term storage areaft 3 1.3 Transport distance from short-term storage to the scaling areaft 1.31.1, 1.2 Transport distance from short-term storage to long-term storageft 2.0 Sifting and Screening Equipment Specifications 2.12.2 Defective batches due to contaminantscount/time 2.22.1 Composed of non-contaminating materialyes/no 2.32.1 Meets the necessary capacitylbs/batch 2.42.3 Change in process time due to sifting and screeningminutes 3.0 Process Improvement Specifications 3.1 Total process time per cycleminutes 3.33.2 Material loss per cyclelbs. 4.0 Ergonomics Specifications 4.14.1, 4.2 Manual Liftinglifting index 4.24.1, 4.2 Reported incidentscount; $$

6. Ergonomics Data Collection  Major Issue: The constant manual lifting tasks required throughout the process is of concern to the customer  Perform the initial analysis using the NIOSH Lifting Equation  Data to collect:  Weight and dimensions of the scaling buckets  Lifting origins and destinations  Worker posture  Lifting frequency  Will determine if further analysis is necessary for any process tasks  Potentially use 3DSSP

7. Layout Data Collection  Major Issues: Inventory is unorganized and there are large transport distances between the storage area and scaling  Obtain existing AutoCAD drawings and verify accuracy  Determine the space constraints within the facility for both storage areas and production areas  Square footage of long-term storage, short-term storage, and production areas  Storage rack capacity  Collect data to determine space requirements  Volume of ingredients used per day, week, month  Pallet dimensions  Volume of ingredients per pallet  Space required to support production process  Current transport distances between storage and scaling

8. Process Data Collection  Major Issues: The current process takes too long, is unpredictable, and work is not standardized  Need to gain a firm understanding of the current process and procedures  A list of dry ingredients and frequency of use  A list of products with associated ingredients and frequency of production  Map process steps and flow  Process cycle time  Task times  Operator utilization  Shrink  Examine current documents used for scaling

9. Equipment Requirements Data Collection  Major Issue: Contaminants get into the mix because there is no equipment to sift and screen the dry ingredients  Need to gain a firm understanding of what Wegmans needs and can support  Current rate of product contamination  Wegmans standards for equipment selection  Capacity requirements  Sanitation procedures and cleaning requirements  Physical space constraints  Manual vs. Automated  Safety issues associated with equipment placement  Contact suppliers to investigate possible solutions