IMPROVEMENT PLAN UPDATESPO 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  Operations Management  Standard Work Implementation

MSD I SUMMARY

PROJECT PLAN – MSD II

ENGINEERING REQUIREMENTS

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 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

Dads 1 operator26 min 15 sec 2 operators15 min 9 sec73% increase

Sub Shop W/ Nuts 1 operator33 min 34 sec 2 operators17 min 38 sec90% increase

Ultimate W/ Nuts 1 operator27 min 50 sec 2 operators16 min 8 sec72% increase

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  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 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  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  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  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  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 DIVIDER  Current Progress:  Collect reasons for changeover  Next Steps:  Collect times for changeover  Create changeover matrix  Present matrix to scheduler

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

DISCUSSION