P10712 CHEESECAKE PROCESS IMPROVEMENT Andreana Crance, Kevin Rodas, Rob Santora, Jeremy Smith, Matt Syska

Meeting Agenda Brief Project Summary 5 min. Project Statement 5 min. System Overview 10 min. Customer Needs & Engineering Specifications 5 min. Risks & Contingencies 5 min. What we have done so far 20 min. Concept Selection 15 min. Target Specs – How we will measure success 10 min. Improvement Ideas 10 min. MSDI Plan of Action 5 min.

P10712 Cheesecake Process Improvement The mission for the cheesecake process improvement is to increase the efficiency and effectiveness of cheesecake production in order to meet customer demand in both quantity and quality of the cheesecakes. Focusing on: Worker Safety Worker Productivity Efficiency of Process Proper utilization of equipment Scrap Reduction

Project Approach  Due to the scattered processes taking place for the cheesecakes, we thought it would be best to break the project into larger categories: Greasing Crumbing Pre-Tunnel Oven Mixing, Pouring, Loading Oven Post-Tunnel Oven Unloading oven, into freezer Slicing Packaging

System Overview

Value Stream Map

Customer Needs & Engineering Metrics

Risks and Contingencies

Process Evaluation Weight GreasingCrumbing Pre-Tunnel Oven Post Tunnel Oven SlicingPackaging Score Efficiency25% Utilization25% Safety25% Equipment10% Scrap15%391339

Pre process clean up Sprayer Calibration Human bending Greasing Efficiency1 Labor1 Ergonomic9 Equipment3 Scrap3 What we have observed in Greasing:

What we have observed in Crumbing:  No Direct Observation as of 10/2/2009  Known Issues:  Uneven distribution of crumbs Leads to scrap issues  Manual process  Nonconformity of crumb size  Crumb displacement at batter drop (pre-oven load) Crumbing Efficiency3 Labor3 Ergonomic3 Equipment9 Scrap9

Pre-Tunnel Pre Oven Efficiency9 Labor9 Ergonomic9 Equipment9 Scrap1 Cluttered area Human bending Labor intensive

Post-Tunnel Post Oven Efficiency1 Labor3 Ergonomic3 Equipment3 Scrap3 Cluttered area Manual process No standards

Slicing Issues  5S issues  Labor Utilization  Material Handling transitions  Scrap Issues  Machine maintenance reactive  TPM – Be proactive!  Staffing setup  Almost identical labels (marble vs. plain)  Lack of Quality Check-One instance of packing defective cheesecake  Walking  2s spin time for machine  Ergonomics – Bending and reaching  Putting covers on causes quality issues / lost productivity  No monitoring of cheesecake time on floor (out of freezer)  Variation in results due to lack of process control Slicing Efficiency9 Labor 9 Ergonomic3 Equipment3 Scrap3

Packaging No dedicated labor Reaching and bending Lack of organization Packaging Efficiency9 Labor3 Ergonomic3 Equipment3 Scrap9

Overall Issues  No standard procedure  No standard location for equipment on floor  Improper/inadequate tools used  Lack of set schedule for cheesecake process  Variable batch sizes  Lack of standard quality checks  Unnecessary movement (time & ergonomics concern)  Current machines may not be ideal  Lack of continuous flow

Concept Selection  Discussion

Target Specifications – Marginal and Target Values Metric No.MetricImportanceUnitsMarginal ValueTarget Value 1 average labor bottleneck utilization 9percentage per year>80%>85% 2risk of injuries9 (benchmarking unit using NIOSH, etc) 25% reduction of benchmarking unit 75% reduction of benchmarking unit 3people travel distance1 % travel distance reduction 10%25% 4 cycle time / cheesecake (minus bake time) 3min. 90% of current cycle time 75% of current cycle time 5 number of defective products 3Percentage scrap 75% of current defect rate 50% of current defect rate 6 number employees on cheesecake process 3employees One employee reassigned More than one employee reassigned 7throughput rate3throughput/hour110% of current value125% of current value 8 process improvement has full ROI for customer 9Years1 Year0.5 Years 9 Solutions meet Wegmans specific health code standards 9Y/NYY 10 Cheesecake retains “homemade” feel 9Y/NYY 11Process changes can meet holiday demand 9Y/NYY

List of Possible Ideas  Efficiency  Standardize batch size  Continuous flow of process  Waste reduction maintenance for equipment: Dropper, greaser, slicer  Standard locations for materials and equipment

List of Possible Ideas  Scrap  Quality Checks: “Defect Board”  Calibration of equipment: Dropper, greaser, etc.  Efficiency, Safety  Reduce total travel distance: people and materials  Efficiency, Safety, Equipment  Eliminating unnecessary motions, providing proper tools

List of Possible Ideas  Crumbing - (Labor Utilization, Scrap, Equipment)  Automated or assisted “Crumber”  Pre/Post Tunnel Oven - (Scrap, Utilization)  Regulate water for baking: volume controlled and assisted  Packaging - (Scrap, Efficiency, Utilization)  Alternative packaging methods

MSDI Plan – Our steps forward