P09713 – Bread and Roll Scaling Room Sponsored by Wegmans R Modern Food Processing and Bakery Technology for Lean Production Systems Kate Gleason Cecilia Enestrom Erik Webster

Roadmap Description and Overview Mission Statement: The Modern Food Processing and Bakery Technology for Lean Production Systems project roadmap lays out a series of projects for the Wegmans bakery facility that will improve major aspects of the company's processes. Each project may be used as a tool to educate RIT students in Lean process improvement techniques and can be iterated many times in the future to provide additional benefits to both Wegmans and the RIT Senior Design Program.

Roadmap Business Goals and Deliverables Identify specific improvement projects within the facility Develop production metrics to evaluate improvements based on the needs and goals of each production line Implement improvement projects to reduce costs associated with wastes and inefficiencies within the facility Properly document all improvements and process changes as these projects are implemented Create process documentation where it is currently lacking

Project Stakeholders Primary Customers: Wegmans Facility and Employees Scott Young, Manufacturing Engineering Manager Chris Isaacson, Industrial Engineer Other Stakeholders: John Kaemmerlen, Faculty Advisor Mark Smith, RIT Senior Design

Project Improvement Process TRACKPhase IPhase IIPhase IIIPhase IV Process Improvement Identify Flow and Current State Waste Reduction Set-up Time and Changeover Reduction Improve Layout Design Safety Improved Documentation and Safety Analysis Implement 5S: Sort, Set in order, Shine, Standardize, Sustain Ergonomic Projects at High Risk Areas Ergonomic Projects at Low Risk Areas Material Handling Identify Material Handling Waste Standardize Material Handling Flow Improve and Implement Material Handling Procedures Metrics Track Current Metrics, Implement Current Metric Documentation Create a Tracking System for Metrics Visual Controls and Documentation for Metrics and System Status (Real-Time) Improve Metrics Equipment Analyze Current Equipment and Maintenance Procedure Create and Implement Documentation for Equipment Update Out-of-Date (bottleneck) Equipment

P09713 Bread and Roll Scaling Room Layout and Process Improvement LinePhase IPhase IIPhase IIIPhase IV Bread and Roll Scaling Room Document current process flow and work practices Identify areas of process and layout improvement Design and implement the new layout Design and implement the new process procedures

Bread and Roll Scaling Room Layout and Process Improvement Project Name Bread and Roll Scaling Room Layout and Process Improvement Project Number P09713 Roadmap R Modern Food Processing and Bakery Technology for Lean Production Systems Start Term End Term Faculty Guide Professor Kaemmerlen (Industrial and Systems Engineering Department) Primary Customer Wegmans Facility and Employees Scott Young Chris Isaacson

Bread and Roll Scaling Room Layout and Process Improvement Current State All scaling and measuring of ingredients for the bread and roll line is performed in the scaling room Currently the ingredients are stored in 50-lb bags which are removed from storage racks by hand, measured on the scale, and moved by cart to their respective areas Double handling of ingredients is occurring at the two scaling locations There is no process for sifting and screening the dry ingredients. This would help reduce debris mixed into the batter The layout is less than optimal, processes and work practices are not standardized, and ergonomics is a major concern

Current Scaling Room

Scale and Bucket

Final Scaling Area

New Scaling Area

Bread and Roll Scaling Room Layout and Process Improvement Mission Statement Document all work practices and processes for the bread and roll scaling operation to promote standardized work, develop a new process and layout for the scaling area that is conducive with Lean practices, and design solutions that will create a sifting and screening process that is ergonomically sound and promotes improved work flow.

Bread and Roll Scaling Room Layout and Process Improvement Key Business Goals/Project Deliverables Document all current processes and work practices Develop alternative processes for scaling the dry ingredients Reduce/eliminate redundancies and double handling in the process Develop a process for sifting and screening the dry ingredients Develop the layout for the new scaling area Identify other opportunities for improvement in the scaling area

Bread and Roll Scaling Room Layout and Process Improvement Assumptions and Constraints Resources for designing solutions and equipment are limited but available. Budget will be constrained based on decisions made by Wegmans Wegmans’ engineering resources are limited but available Space is limited in the area where the scaling process will be located and existing materials in the area will be relocated or eliminated The bread and roll line will be moving to a new location near the new scaling location in the future

Bread and Roll Scaling Room Layout and Process Improvement Preliminary Customer Needs Relocate and redesign the layout for the scaling area near the bread and roll line Improve the safety and ergonomics of the process Develop a process for sifting and screening dry ingredients Eliminate double handling of dry ingredients Document and standardize process procedures Identify and implement Lean process improvements

Preliminary Risk Assessment Cost/Budget Insufficient funds to design and implement solutions for sifting and screening Customer Approval Wegmans does not approve of the solutions developed by the project team Space Restrictions The area reserved for the new scaling area will not support the process that is developed by the project team Bread and Roll Scaling Room Layout and Process Improvement

Bread and Roll Scaling Room Layout and Process Improvement Staffing Requirements NameDisciplineRole John Kaemmerlen Faculty Guide Faculty Guide, will work closely with the team on an on- going basis to facilitate success of project. Cecilia Enestrom IEWill serve as Co-Project Manager and focus on the design of the new layout. Kate GleasonIEWill serve as Co-Project Manager and concentrate on developing the new scaling processes. Erik WebsterIEWill serve as Co-Project Manager and concentrate on the design and ergonomics of the new sifting and screening process. TBDMEDevelop new equipment for sifting and screening process. TBDMEDevelop new equipment for new layout and scaling processes.

Bread and Roll Scaling Room Layout and Process Improvement Preliminary Work Breakdown Structure PersonWeek 0-1 TasksWeek 1-2 TasksWeek 2-3 Tasks Cecilia Enestrom – Co- Project Manager Meet to discuss specific team assignments. Review current layout and new area available in AutoCAD Take necessary measurements in current and new area Kate Gleason – Co-Project Manager Meet to discuss specific team assignments. Observe current processes and work flow Document current processes and work flow Erik Webster – Co-Project Manager Meet to discuss specific team assignments. Observe current procedures and qualitatively measure ergonomics Quantitatively measure the ergonomics of current procedures MERead through project located on EDGE website. Gain an understanding of the process Measure parameters that are related to design solutions MERead through project located on EDGE website. Gain an understanding of the process Measure parameters that are related to design solutions

Questions?