R 09710 Modern Food Processing and Bakery Technology

R 09710 - Modern Food Processing and Bakery Technology for Lean Production Systems Sponsored by Wegmans Levi Stuck Evan De. Cotis Kate Gleason Stephanie Rager Cecilia Enestrom Bruno Coelho

Project 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. Project Objective: Identify and implement improvement projects throughout different areas within the Wegmans bakery facility. This project family will examine several production lines within the facility and present improvement projects that can be performed on each line. The necessary projects and improvement techniques will vary among the production lines because they all operate independently. Some projects may include: Lean improvement, safety and ergonomics, material handling, layout

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

Affinity Lean Diagram Change Manufacturing Mindset Quality Control Interdepartmental Communication Knowledgeable Resources Process Analysis 5 S Program 5 S Policy Kaizen System Find the Herbie Station Standardization Seasonal Accommodations ERP - Metrics, Utilization Seasonal Product Procedures Establish Usable Metrics Flow (Apparent) Lean Production Metrics Poor Flow Across Facility Performance Metrics Improved Flow Performance Metrics Visual Aids Standardization for Changeovers TIMWOOD Metrics Implement a Pull System Standardization Value Stream Mapping Standards for Processes No Set Standards Line Rates Models, Assess Daily Performance Lean Set-up Training Program Sanitation Procedures Improve. Material Flexibility with Seasonal Products Handling/Logistics Lots of Manual Transport Material Handling Improved Material Handling Logistics Analysis In-house Logistic Issues Logistics in Each Area Proper Labor Allocation Improved Labor Staffing More Engineering Resources Facility Space Constraints Equipment Upgrades Updated Facilities Plan and Layout Automation Safety Improved Ergonomics Create Ergo Team Sanitation Safety Ergonomics Ergonomic Changeovers Issues Changeovers/Set-up Preventative Ergonomic Evaluation times Packaging Maintenance Improved Packaging Preventative Maintenance Packaging Issues Procedures Standardization in Maintenance Weight

Objective Tree Resources Scope Economics Technology People: Senior Design Students Wegmans Engineers Documentation for Reiteration of Projects Three to Five Years ROI for Capital Investments Wegmans Current Bakery Machinery and Product Lines Equipment: Production Lines at Wegmans Toyota Production Systems Lab Useful for Engineers Interested in Process Improvements Cost of Time and Production to Implement Changes Mostly ME/IE Content Time: 22 Weeks per Project Small Kaizen Projects to Start, Larger Projects in the Future Low to No Direct Costs for Most Projects Easy to Implement for Wegmans Employees and Engineers

Project Roadmap TRACK Process Improveme nt Phase III Set-up Time and Changeover Reduction Phase IV Improve Layout Design Identify Flow and Current State Waste Reduction Safety Improved Documentation and Safety Analysis Implement 5 S: Sort, Set in order, Shine, Standardize, Sustain Ergonomi c Ergonomic Projects at High at Low Risk Areas Material Handling Identify Material Handling Waste Standardize Material Handling Flow Improve and Implement Material Handling Procedures Controls Track Current Metrics, Implement Current Metric Create a Tracking System for Metrics Visual Controls and Documentation for Metrics and Improve Metrics

Process Improvement Objectives: • Identify and document current flow of material through the lines • Identify areas creating the most waste and implement reduction techniques • Identify longest setup/ changeover times and reduce it Potential Projects Provided by Wegmans: • Fresh Roll Line Shrink Reduction • Par. Bake Shrink Reduction • Pastry Area improved layout Constraints: • Implementing the change, workers against change Resources: • Industrial Engineers: analyze flow, find waste, lean production techniques • Mechanical Engineers: design of alternatives in setup reduction

Project Roadmap TRACK Process Improveme nt Phase III Set-up Time and Changeover Reduction Phase IV Improve Layout Design Identify Flow and Current State Waste Reduction Safety Improved Documentation and Safety Analysis Implement 5 S: Sort, Set in order, Shine, Standardize, Sustain Ergonomi c Ergonomic Projects at High at Low Risk Areas Material Handling Identify Material Handling Waste Standardize Material Handling Flow Improve and Implement Material Handling Procedures Controls Track Current Metrics, Implement Current Metric Create a Tracking System for Metrics Visual Controls and Documentation for Metrics and Improve Metrics

Safety Objectives: • Look at current documentation for safety incidents and complaints • Create new and improved documentation • Create safety training for employees for reporting incidents or for safe procedures Potential Projects Provided by Wegmans: • Work with the Ergonomics Team • Improve Ergonomics of Pastry Area Constraints: • May not be able to update current equipment • Unable to adjust any lifted weight Resources: • Industrial Engineers: analyze ergonomic factors, develop alternatives • Mechanical Engineers: design of alternatives

Project Roadmap TRACK Process Improveme nt Phase III Set-up Time and Changeover Reduction Phase IV Improve Layout Design Identify Flow and Current State Waste Reduction Safety Improved Documentation and Safety Analysis Implement 5 S: Sort, Set in order, Shine, Standardize, Sustain Ergonomi c Ergonomic Projects at High at Low Risk Areas Material Handling Identify Material Handling Waste Standardize Material Handling Flow Improve and Implement Material Handling Procedures Controls Track Current Metrics, Implement Current Metric Create a Tracking System for Metrics Visual Controls and Documentation for Metrics and Improve Metrics

Material Handling Objectives: • Identify and document current material handling procedures • Identify material handling waste (excess walking, manual) • Develop alternatives in order to eliminate waste Potential Projects Provided by Wegmans: • Create standardized bake racks to be used throughout entire facility • Fresh Bread & Roll Scaling Project- develop method to “sift and screen” materials during the scaling process Constraints: • May not be able to update current equipment • Unable to automate a manual process Resources: • Industrial Engineers: analyze current system and documentation, identify waste • Mechanical Engineers: design of alternatives

Project Roadmap TRACK Process Improveme nt Phase III Set-up Time and Changeover Reduction Phase IV Improve Layout Design Identify Flow and Current State Waste Reduction Safety Improved Documentation and Safety Analysis Implement 5 S: Sort, Set in order, Shine, Standardize, Sustain Ergonomi c Ergonomic Projects at High at Low Risk Areas Material Handling Identify Material Handling Waste Standardize Material Handling Flow Improve and Implement Material Handling Procedures Controls Track Current Metrics, Implement Current Metric Create a Tracking System for Metrics Visual Controls and Documentation for Metrics and Improve Metrics

Controls Objectives: • Track and implement current metrics and documentation • Create a tracking system for metrics • Visual controls and documentation for metrics in real-time • Improve metrics for more detailed tracking Constraints: • No current metric system in place • Lack of historical data Resources: • Industrial Engineers: Analyze areas where tracking is needed most • Mechanical Engineers: Construction of control systems • Electrical/Computer Engineers: DAQ system for tracking, electronics of control systems.

Project Roadmap TRACK Process Improveme nt Phase III Set-up Time and Changeover Reduction Phase IV Improve Layout Design Identify Flow and Current State Waste Reduction Safety Improved Documentation and Safety Analysis Implement 5 S: Sort, Set in order, Shine, Standardize, Sustain Ergonomi c Ergonomic Projects at High at Low Risk Areas Material Handling Identify Material Handling Waste Standardize Material Handling Flow Improve and Implement Material Handling Procedures Controls Track Current Metrics, Implement Current Metric Create a Tracking System for Metrics Visual Controls and Documentation for Metrics and Improve Metrics

Equipment Objectives: • Identify outdated and/or bottleneck equipment • Research new alternatives or upgrades • Implement feasible equipment changes and upgrades along with preventative maintenance solutions Potential Projects Provided by Wegmans: • Creation of preventative maintenance procedures for bakeshop equipment Constraints: • Large scale custom assembly lines • Expensive • Integration issues • High volume of product so durability is crucial Resources: • Industrial Engineers: analyze current system and documentation, identify waste • Mechanical, Electrical, Computer Engineers: design of alternatives

Project Constraints/Restrictions Over Utilization of Industrial Engineering Resources Lean work Customer needs fulfillment Process Improvement Large amount of observation time Implementation delays 6 teams = 42+ people on mfg floor (Manageable? )

Questions?