R09710 - Modern Food Processing and Bakery
Technology for Lean Production Systems
Sponsored by Wegmans
Levi Stuck
Evan DeCotis
Kate Gleason
Stephanie Rager
Cecilia Enestrom
Bruno Coelho
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.
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
TRACK
Phase I
Phase II
Phase III
Phase IV
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)
Equipment
Analyze Current
Equipment and
Maintenance Procedure
Process
Improvement
Identify Flow and
Current State
Improve
Metrics
Create and Implement
Update Out-of-Date (bottleneck)
Documentation for
Equipment
Equipment
Automation/Improvement of Packaging on the Cookie Line
Line
Phase I
Phase II
Cookie Line
Automation
Automated
Scaling of
Cookies
Automated
Scaling of other
Products
Phase III Phase IV
Automated
Packaging for
Cookie Line
Integration of
Systems
Automation/Improvement of Packaging on the Cookie Line
Automation/Improvement of Packaging on the Cookie Line
Automation/Improvement of Packaging on the Cookie Line
Project Name
Automation/Improvement of Packaging on the Cookie Line
Project Number
P09711
Roadmap
R09710- Modern Food Processing and Bakery Technology for Lean Production Systems
Start Term
2008-2
End Term
2008-3
Faculty Guide
Professor Kaemmerlen (Industrial and Systems Engineering Department)
Primary Customer
Wegmans
Scott Young
Chris Isaacson
Automation/Improvement of Packaging on the Cookie Line
Project Summary
 Wegmans bakes and packages all of their mini cookies at their
bakeshop located here in Rochester on Brooks Avenue.
 Currently the packaging is done by six or seven people who stand
around a conveyor and pull the cookies into the clam-shell packages.
 Employees should be packing 398 grams into a package
 Employees are packing sometimes up to 450 grams of cookies
 This is a loss for Wegmans because customers are receiving more cookies
than they are paying for.
 This project will look into building an automated prototype that will
separate the cookies into the correct amount by weight, which the
employees can then package.
Automation/Improvement of Packaging on the Cookie Line
Mission Statement
 Create an automated prototype that will separate mini
cookies by weight, while preventing cookies from
moving on in the process until a specified weight is
reached. It will create a clear separation between the sets
of cookies that go into each package without
substantially slowing down the packaging process.
Automation/Improvement of Packaging on the Cookie Line
Key Business Goals/Project Deliverables
 Provide an effective design to minimize the packaging
wastes
 Research materials and sensors to be used in automated
prototype
 Produce an automated prototype
 Test/analyze effectiveness of prototype
 Present prototype to customer
Automation/Improvement of Packaging on the Cookie Line
Assumptions and Constraints
 Budget
 Wegmans’ engineering resources
 Scheduling of benchmarking/testing time due to
production goals
 Should not substantially slow down the packaging
process
Automation/Improvement of Packaging on the Cookie Line
Preliminary Customer Needs
1. Weights Product
1.1 Mini-Cookies
1.2 Mini-Muffins
1.3 Brownie Bites
2. Long Term Solution
2.1 Adjustable
3. Randomization
4. Waste Reduction
4.1 Reduces the amount of excess cookies in package
Automation/Improvement of Packaging on the Cookie Line
Preliminary Risk Assessment
 Cost/Budget
 Consequences- could not produce prototype
 Substantially slows down process
 Consequences- not useful in line, no implementation
 Technology- needed technology is not available
 Consequences- unable to produce effective prototype
 Reduce Quality- design effects cookies
 Consequences- design and prototype cannot be implemented
Automation/Improvement of Packaging on the Cookie Line
Staffing Requirements
Name
Discipline
Role
John
Kaemmerlen
Faculty Guide
Faculty Guide, will work closely with the team on an on-going basis to
facilitate success of project.
Stephanie Rager IE
Will serve as Project Manager. Assist in identifying the current process for
packaging. Perform analysis on current process to be used as a benchmark for
testing final prototype.
Bruno Coelho
ME
Will serve as Chief Engineer. Act as main point of contact from an
engineering standpoint. Assist in creation and production of an effective
prototype.
TBD
ME
Establish an effect engineering design for project. Research materials to be
used in prototype.
TBD
EE
Research sensors to use to collect the weight of the cookies. Program sensors
to be used in prototype.
TBD
EE
Research proper electronics to be used in mechanical system. Implement
electronics in system/prototype.
Automation/Improvement of Packaging on the Cookie Line Preliminary
Work Breakdown Structure
Person
Week 0-1 Tasks
Week 1-2 Tasks
Week 2-3 Tasks
Stephanie Rager – Project
Manager
Meet with Bruno to discuss specific
team assignments. Set up first
meeting before Friday. Conduct the
meeting, and provide each group
member with their assignments to be
completed by the next Fridays
meeting.
Organize a site visit to Wegmans for
entire team. Conduct a
brainstorming session with project
team to generate initial design ideas.
Review the project schedule with the
project team.
Compile research performed in
various fields by the project team.
Organize and conduct a team
meeting to monitor individual
progress. Address areas of conflict
with individual team members as
they apply to them.
Bruno Coelho – Chief
Engineer
Meet with Stephanie to discuss
specific team assignments. Assist in
conducting the meeting and provide
overview of project to team
members.
Conduct a brainstorming session
with the project team to generate
initial design ideas. Provide each
group member with their
assignments to be completed by the
next Fridays meeting.
Generate concept design of
mechanical system. Organize and
conduct meeting with team to
discuss individual concept designs.
Provide team members with their
assignments to be completed by the
next Fridays meeting.
ME
Familiarize themselves with the
project by thoroughly examining the
project readiness package located on
the EDGE website.
Research possible materials to be
used in the mechanical system.
Brainstorm some individual design
ideas.
Generate concept design of
mechanical system. Continue to
researching materials to be used in
mechanical system.
EE
Familiarize themselves with the
project by thoroughly examining the
project readiness package located on
the EDGE website.
Research possible sensors to use in
collecting weight. Brainstorm some
individual design ideas.
Generate concept design of
researched sensors. Continue
researching sensors to use in
collecting weight.
EE
Familiarize themselves with the
project by thoroughly examining the
project readiness package located on
the EDGE website.
Research possible electronics to use
in the mechanical system. Brainstorm
some individual design ideas.
Generate concept design of
electronics to be used in mechanical
system. Continue researching
electronics to be used in mechanical
system.
Bread and Roll Scaling Room Layout and Process
Improvement
Line
Bread and
Roll Scaling
Room
Phase I
Phase II
Phase III Phase IV
Document
Identify areas of
Design and
current process
process and
implement the
flow and work
layout
new layout
practices
improvement
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
R09710- Modern Food Processing and Bakery Technology for Lean Production Systems
Start Term
2008-2
End Term
2008-3
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
Bread and Roll Scaling Room Layout and Process Improvement
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
Staffing Requirements
Name
Discipline
Role
John
Kaemmerlen
Faculty
Guide
Faculty Guide, will work closely with the team on an ongoing basis to facilitate success of project.
Cecilia
Enestrom
IE
Will serve as Co-Project Manager and focus on the design
of the new layout.
Kate Gleason
IE
Will serve as Co-Project Manager and concentrate on
developing the new scaling processes.
Erik Webster
IE
Will serve as Co-Project Manager and concentrate on the
design and ergonomics of the new sifting and screening
process.
TBD
ME
Develop new equipment for sifting and screening process.
TBD
ME
Develop new equipment for new layout and scaling
processes.
Bread and Roll Scaling Room Layout and Process Improvement Preliminary
Work Breakdown Structure
Person
Week 0-1 Tasks
Week 1-2 Tasks
Week 2-3 Tasks
Cecilia Enestrom – Co- Meet to discuss specific Review current layout
Project Manager
team assignments.
and new area available
in AutoCAD
Take necessary
measurements in
current and new area
Kate Gleason –
Co-Project Manager
Meet to discuss specific Observe current
team assignments.
processes and work
flow
Document current
processes and work
flow
Erik Webster –
Co-Project Manager
Meet to discuss specific Observe current
team assignments.
procedures and
qualitatively measure
ergonomics
Quantitatively measure
the ergonomics of
current procedures
ME
Read through project
located on EDGE
website.
Gain an understanding
of the process
Measure parameters
that are related to
design solutions
ME
Read through project
located on EDGE
website.
Gain an understanding
of the process
Measure parameters
that are related to
design solutions
Commercial Roll Line Shrink Reduction
Project Name:
Commercial Roll Line Shrink Reduction - P09712
Roadmap:
Modern Food Processing and Bakery Technology for Lean
Production Systems - R09710
Start Term: 2008-2
End Term: 2008-3
Faculty Guide:
John Kaemmerlen (Industrial and Systems Engineering
Department)
Roadmap Function
Line
Commercial
Roll Line
Shrink
Reduction
Phase 1
Phase 2
Phase 3
Phase 4
Identify and
Focus on the
Re-evaluate flow Reiterate process,
construct current
process
of rolls, create a focusing on low
state value stream improvement of a new benchmark. cost projects to
map
specific target area
Formal
improve line
presentation to
performance
stakeholders
Project Summary
Commercial Roll Line Shrink Reduction, is sponsored by
Wegmans. The project goals are to decrease the amount of wasted
dough and baked rolls. Wegmans estimates between $5,000 and
$10,000 are lost on a typical day of production on this line. About
8% of the product put into the system will be removed as waste.
We will be responsible for analyzing, suggesting, implementing,
and recording the overall results of our actions. Our team will be
providing support for the Wegmans bakery on Brooks Avenue in
Rochester NY. This bakery is responsible for the majority of the
baked goods available in the 72 Wegmans stores.
Objectives and Project Deliverables
 Eliminate TIMWOOD
 Identify and implement flow
 Move current state towards lean operation
 Establish metrics
 Research in house equipment optimization
 Repair/update bottleneck equipment
 Project progress presentation
Assumptions and Constraints
Constraints
 Budget will be based on
ROI
 Large scale investments
will be limited to later
iterations
 The bread and roll line
may be moving to a new
location in the future
 Line breakdowns
Assumptions
 Some of the improvements
made on the roll line may
also be implemented on the
bread line
 Employees will have buy in
to the project
Operation Introduction
 High volume
 Highly automated with human integration
 Dough pump to shipping dock process
 Commercial hot dog and hamburger rolls
 Thursday and Friday operation during off-season
 4500 rolls/hr
 5% - 10% defect rate
 $5,000 - $10,000 waste daily
Rounding
Dough Pump
Dough Form and Batch
Dough Rest Conveyor
Panning
Dough drops onto
conveyors
Dough drops into pans and pans
are manually loaded onto rack
Proof Box
Entrance
Exit
Oven
Entrance
Exit
Roll removal/cooling Conveyor
Suction Rolls From Pans to
Cool down
Convey to Cool and Enter
Packaging
Packaging
Slicer
Bagging
Staffing Requirements
Name
Discipline
Role
John
Kaemmerlen
Faculty
Guide
Faculty Guide, will work closely with the team on an on-going basis to
facilitate success of project.
Levi Stuck
IE
Dual project lead. Facilitate project direction.
Evan DeCotis
IE
Dual project lead. Manage task assignment and resource allocation.
TBD
IE
Develop plan to reduce amount of people needed on the roll line. Use
knowledge of statistics and Design of Experiments to analyze
current/future state. Will also be required to perform basic time studies
to help fully understand the process.
TBD
ME
Will be responsible for reducing waste caused specifically by machines.
Must understand the mechanical process by which the dough travels
through the system, and how it is processed at each machining station.
TBD
ME
Duties will include improving the overall process by which the dough
flows through the system. Efforts of improvement should be focused on
handling procedures, conveyors, and overall time management.
Preliminary Work Breakdown Structure
Person
Week 1
Week 2
Week 3
Levi Stuck
Facilitate team growth and ensure
project buy-in and participation.
Set project goals and perform a
preliminary analysis of what
steps need to be performed.
Prepare for formal presentation
with Wegmans. Ensure all
stakeholders are aware of what
steps will be taken in the next 19
weeks.
Evan
DeCotis
After site visit, lead
brainstorming exercise to gather
preliminary ideas for
improvement.
Narrow down list of ideas to a
handful of manageable tasks.
Create a Value Stream Map of
current process.
Gather all required documents
from team for a project review
before formal presentation.
IE
Become familiarized with process
with a site visit. Record
observations, ideas, comments,
and questions.
2nd site visit, focus on people.
Draft project proposals based on
data and information gathered.
Finish all documentation regarding
roll line shrink reduction for
presentation and reports.
ME
Become familiarized with process
with a site visit. Record
observations, ideas, comments,
and questions.
2nd site visit, focus on machines.
Draft project proposals based on
data and information gathered.
Finish all documentation regarding
roll line shrink reduction for
presentation and reports.
ME
Become familiarized with process
with a site visit. Record
observations, ideas, comments,
and questions.
2nd site visit, focus on process.
Draft project proposals based on
data and information gathered.
Finish all documentation regarding
roll line shrink reduction for
presentation and reports.
Project Roadmap
Line
Phase I
Phase II Phase III Phase IV
Cookie Line
Automation
Automated
scaling of
cookies
Automated
scaling of other
products
Automated
packaging for
cookie line
Integration of
systems
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
Identify and
Focus on the
Re-evaluate flow
Reiterate
Commercial
process
of rolls, create a process, focusing
Roll Line construct current
state value
improvement of a new benchmark.
on low cost
Shrink
stream map
specific target
Formal
projects to
Reduction
area
presentation to
stakeholders
improve line
performance
Questions?