PROJECT STATUS UPDATE
P10711 & P10712
Andreana Crance, Industrial & Systems Engineering
Matt Syska, Industrial & Systems Engineering
PROJECT STATUS UPDATE
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Project Name
 Wegmans SD Projects 1 & 2
Project Number
 P10711 & P10712
Project Family
 R09170
Track
 Modern Food Processing and Bakery Technology for Lean Production Systems
Start Term
 2009-2
End Term
 2009-3
Faculty Guide
 Dr. John Kaemmerlen (ISE)
Technical Lead
 Phil Bryan
Primary Customer
 Wegmans Distrubution Center, Scott Young
PHASE 0: PLANNING: MISSION STATEMENT
Product Description /Project Overview
The aim of this project is to improve a specific process in the Wegmans manufacturing facility., focusing on the
Central Bakeshop or Culinary Innovation Center. The overall outcome of the project is to identify and
implement process improvements in order to increase efficiency, and therefore throughput of the process.
Key Business Goals/Project Deliverables The primary business goals of this process change is to:
Create
standard work processes for different areas of facility
Standardize procedures (i.e. changeovers, storage)
Utilize workers’ time in a more efficient way
Improve overall efficiency of facility in order to make a greater profit
Improve safety conditions for all workers
Primary Market /Project Opportunities
Wegmans central bakeshop and culinary innovation center in Rochester, NY
Secondary Market /Project Opportunities
Similar Wegmans production facilities
Stakeholders
Wegmans Central Bakeshop and Culinary Innovation Center in Rochester, NY
Scott Young and Wegmans’ engineering group
Bakery and Culinary workers whom are effected by the changes
Raw Material and Ingredients Providers
Wegmans Distribution Center Community
Community that purchases the products
PHASE 1: CONCEPT DEVELOPMENT
IDENTIFY CUSTOMER NEEDS - INTERVIEWS
Primary Customer(s)
Wegmans Engineering Team
Scott Young: Provided many ideas for new projects for 2009 year. Provided insight
into the projects.
Additional
resources include: Mike Least (Manufacturing Engineer), Chris Isaacson, Jamie
Rothfuss (Industrial Engineer)
In
next 1-2 weeks: Contact Mike, Chris and Jamie to narrow down projects
Other Stakeholder(s)
Wegmans Bakery and Culinary Workers
 Following facility tour and project selection: Must talk with bakery and culinary
workers to get their input and feedback
Past Senior Design Team(s)
P09711 – Automation and Improvement of Packaging on the Cookie Line
Automating a perviously all hands-on process
P09712 – Commericial Roll Line Shrink Reduction
Decrease amount of wasted rolls and improve effeciency of process
P09713 – Bread and Roll Scaling Room
Make overall layout of room more efficient and effective for employees
PROJECT CONTEXT
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Wegmans operates a Central Bakeshop and Culinary
Innovation Center in Rochester, NY.
2008-2009 AY first year for Wegmans projects.
DPM students in Fall 2008 defined 6 potential projects.
Packaging
Automation/Improvement
for Cookie Line
Fresh Bread and Roll
Scaling Room
Commercial Bread Line
Shrink Reduction
ERP
ERP Implementation
Implementation
Ergonomics
Ergonomics
Universal
System
Universal Rack System
CURRENT WORK
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P09711 – Cookie Line Automation
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P09712 – Commercial Bread Line Shrink
Reduction
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P09713 – Fresh Bread and Roll Scaling Room
FUTURE WORK BASED ON CURRENT WORK
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Re-evaluated projects defined in Fall 2008
DPM with Wegmans:
Packaging
Automation/Improvement
for Cookie Line
Fresh Bread and Roll
Scaling Room
Commercial Bread Line
Shrink Reduction
ERP Implementation
Implementation
ERP
Ergonomics
Ergonomics
Universal Rack
Universal
Rack System
System
AFFINITY DIAGRAM –
RAW DATA FROM CUSTOMERS AND STAKEHOLDERS
Lean
No
Standardization
Safety
Ergonmics
Concerns
Material
Handling
Layout Design
Worker
Relations
Transport of raw
materials
New
Equiptment
More efficient
set ups
Culinary
Innovation
Center more
strict
Manual process
operation
improvements
Easily cleaned
Must meet
health code
High Volume,
High Mix of
products
Noise Issues
Mixing
Storage
Utilization
Batch
Processing &
Bulk Savings
Preventative
Procedures
Transferrable
Low cielings
Process
Improvement
Cost effective
Labor
Effeciency
Savings
Loading
Procedures
Sanitary
Requirements
Customizable
Resource Usage
Ease of Use
Scalable
Environmentally
friendly
OBJECTIVE TREE –
WHY DOES THE CUSTOMER NEED THIS PRODUCT?
This Product or
Process
Needs to …
Lean Processes
Improve
Loading
Procedures
Scalable
solution
Safety
Proper
utulization of
resoruces
Ensure safety of
workers
Material
Handling
Handle variety
of materials
Improve storage
of large raw
material
Stop problems
before they
occur
Reduce current
noise issues
Layout
Transferrable
Effeciently use
old and new
space
Enable further
expansion
Cost effective
changes
FUNCTION TREE –
WHAT DOES THIS PRODUCT NEED TO DO?
Improve Process’ at Wegmans
Central Bakeshop and
Culinary Innovation Center
Reduce time to load
and unload machines
Lean
Safety
Able to be sized up
due to high demands
Be proactive in
solving safety
problems – report any
issues
Perform to the
bottleneck
Perform to the set
standards
Material Handing
Handle up to 2,000lbs
of material
Accessible and cost
efficient storage
Not bring noise levels
above acceptable
standard
Layout
Able to move facility to
facility without failing
Improve flow of goods
and people
Effectivley use space
in order to allow for
expansion
Be cost effective
PRELIMINARY IDEAS
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Ergonomics and Design of Tumbler Transport
Storage Utilization Standardization
Bakery Patisserie Efficiency
Noise Exposure Ergonomics Issue
Handling System for Meat Marinade
Bakery Bulk Bag Storage
Bakery Cheesecake Process Improvement
Batch Prep Room Simplification
Marinade Package Labeling Improvement
Tote (basket) Loading Process Improvement
PROJECT RISKS + RESTRAINTS
Wegmans staff very busy
 Must be completed in 22 weeks
 Wegmans does not have hard deadlines
 Working with peoples’ workplaces
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FUTURE PLAN
WHERE DO YOU GO FROM HERE?
Action
Date
Meet with faculty guide and tech lead to discuss possible
projects
Set up facility tour with Wegmans Contacts
Week 6/7
Analyze Projects
Week 7/8
Discuss Top Project Choices with Wegmans
Week 8/9
Week 6/7