Wegmans Frozen Cookie Capacity Increase
Final Project Presentation
Richard Latham, Bridget Eggers, Tyler
Brent, Valeria Gonzalez
A DAY IN THE PROCESS
Frozen Cookies
Commercial Cookies
Problem Definition
Current state
Target state
 High variability in and around the
 Establish synchronized flow between
production line
 There is a bottleneck at mixing
scaling, mixing, dividing, and packaging
steps
 Underutilization of resources
 Increase production capacity
 Staffing issues
 Maximize resources utilization
 Need for overtime
 Reduce/Eliminate the need for overtime
 Lack of standardization
 Implement standardized work
 Production delays
 Establish schedule flexibility
 Track and sustain production system
Observations
 Variability derives from other production lines that
are sharing resources
 Changeover time is not accounted for in scheduling
 Planned vs. Actual cycle times are not consistent
 Labor intensive tasks on Mixer yields high
variability in cycle times
 Unplanned production adjustments affect
scheduled availability of shared resources
Customer needs & Eng. Requirements
Engineering Metrics
Score
27
18
36
72
57
21
18
27
39
Engineering Requirement
Measure of Performance
Food safety risks
Ergonomic impacts
Quality impacts
Throughput
Rate of occurences
Ergonomic Study, Before/After
Rate of occurences
Production efficiency percentage
Variability and production efficiency
Characterization of all process steps percentage
Manufacturing Manager, Bakeshop
Production Area Manager,
Manufacturing Engineer, Line Team
Leader and Production Line Workers
agree with proposed solutions.
Evaluation checklist
Implemented solution are consistent
across crews and shifts.
Binary (yes/no)
Tools that make system run
smoothly.
Sustainable solution methods.
Current vs. Future productivity rate
Evaluation checklist
Ideal Value
0
0
0
100% +/- 0%
Marginal
Value
0
0
0
90% +/- 10%
100%
85%
All agree
All agree
Yes
Yes
20% inc mixer
10% inc
10% inc mixer
divider
5% inc divider
All agree
All agree
Proposed Solutions
Improvement Task
Priority
Objective
Operations Management
Update schedule with more accurate times
Add Changeover time into schedule
Offset break schedules so another operator can run the mixer
Add in breaks of workers into schedule if breaks cannot be offset
1
Make mixer its own resource and develop a single daily
mixer schedule.
Create changeover matrix for mixer and divider for use in
scheduling.
A way to know if there is enough time to do more batches for the night
Have schedule of spiral 2 and commercial oven line up better
Mixer schedule located by the mixer
Mixing Prep Activities
Do justification analysis to have a part timer help open boxes when mixing choc chip
cookies
2
To make a decision about whether a second operator is
justifiable in the frozen cookie mixer process (for cookies
with inclusions).
Mixing Clean Up Kaizen
Create system that allows the sanitation employee to be at the mixer at the required
time to clean it
3
Create a system that allows the sanitation employee to be
at the mixer at the right time.
4
Create work instructions for revised process
improvements
5
Increase usability of recipe by removing the need for
calculations to find the number of bags/boxes needed.
Standard Work Implementation
Provide Work Instructions
Scaling Process improvement
Modify cookies recipes format
Operations Management
To
Cookie Cookie
Pucks- Pucks-No
W/Nuts
Nuts
Product
From
Machine
Cookie PucksW/Nuts
Cookie PucksNo Nuts
Frz Choc Chip
Cooky
TO BE DISCD
ULT Choc Chip
Sheets
NEW
Frz Ult ChChp
Cooki 1.1oz
Frz Ult ChChp
Nuts 1.1oz
Frz Chc Chc
Chunk Cky 1.1
Frz Oatmeal
Raisin 1.1oz
Frz Pnut Btr
Cookie 1.1oz
Frz 1.1 Coconut
Macaroon
Frz
Snickerdoodle
Pucks
Frz Meltaway
Cookie
Frz Sugar Cut
Out Circles
Frz Sugar sheet
cut out
Frz Ult
ChChp
Cooki
1.1oz
Frz Ult
ChChp
Nuts
1.1oz
Frz Chc
Chc
Chunk
Cky 1.1
Frz
Frz Pnut Frz 1.1
Frz
Frz
Frz Sugar Frz Sugar Rectangl
Oatmeal
Btr
Coconut Snickerd
Meltawa Cut Out sheet cut e Breton
Raisin
Cookie Macaroo oodle
y Cookie Circles
out
Dough
1.1oz
1.1oz
n
Pucks
Square
Breton
Dough
Frz
Wg
Wg
Gingerbr
Chocolat
Oatmeal
Cherry
ead cut
e Hazel
& Fruit
Almond
out
'Nuttin
Cookie
sheets
Cookie
Frz Tree
Breton
Dough
Rustic
Fruit
Vemag + Vemag + Vemag +
Water
Water
Hand
Wheel
Wheel
Press
Vemag
Vemag
W/U
W/U
W/U
U
W/U
W/U
W/U
W/U
W/U
W/U
W/U
W/U
W/U
Vemag
W/U
X
60
60
60
60
20
60
60
60
60
60
60
60
40
40
40
40
40
40
60
60
60
W/U
0
X
22
22
22
22
22
60
60
60
60
60
60
40
40
40
40
40
40
60
22
Unifiller Unifiller Unifiller
60
22
22
X
22
22
22
22
60
60
60
60
60
60
40
40
40
40
40
40
60
60
60
W/U
U
22
22
22
X
20
20
60
60
60
60
60
60
60
40
40
40
40
40
40
60
22
60
W/U
22
22
22
22
X
0
22
60
60
60
60
60
60
40
40
40
40
40
40
60
22
60
W/U
22
60
60
60
60
X
60
60
60
60
60
60
60
40
40
40
40
40
40
60
60
60
W/U
22
22
22
22
20
20
X
60
60
60
60
60
60
40
40
40
40
40
40
60
60
60
W/U
60
60
60
60
60
60
60
X
60
60
60
60
60
40
40
40
40
40
40
22
60
22
W/U
60
60
60
60
60
60
60
60
X
60
60
60
60
40
40
40
40
40
40
60
60
60
W/U
60
60
60
60
60
60
60
60
60
X
60
60
60
40
40
40
40
40
40
60
60
60
W/U
22
22
22
22
22
22
22
22
22
22
X
22
22
40
40
40
40
40
40
22
22
22
W/U
22
22
22
22
22
22
22
22
22
22
22
X
22
40
40
40
40
40
40
22
22
22
W/U
22
22
22
22
22
22
22
22
22
22
22
22
X
40
40
40
40
40
40
22
22
22
Vemag
40
40
40
40
40
40
40
40
40
40
40
40
40
X
20
20
20
20
22
40
40
40
40
40
40
40
40
40
40
40
40
40
40
40
40
20
X
20
20
20
22
40
40
40
40
40
40
40
40
40
40
40
40
40
40
40
40
20
20
X
20
20
22
40
40
40
40
40
40
40
40
40
40
40
40
40
40
40
40
40
40
40
40
40
40
40
40
40
40
40
40
40
20
20
20
20
20
20
X
20
20
X
22
40
40
40
22
40
40
40
40
40
40
40
40
40
40
40
40
40
40
40
40
60
60
60
60
60
X
40
40
40
60
60
60
60
60
60
60
60
60
60
60
60
60
40
40
40
40
40
40
X
60
22
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
40
40
40
40
40
40
40
40
40
40
60
X
60
60
60
60
40
60
40
60
60
X
Vemag +
Water
Wheel
Vemag +
Square Breton
Water
Dough
Wheel
Vemag +
Frz Tree Breton
Hand
Dough
Press
Rustic Fruit
Vemag
Rectangle
Breton Dough
Frz Gingerbread
cut out sheets
Wg Oatmeal &
Fruit Cookie
Wg Chocolate
Hazel 'Nuttin
Cookie
Cherry Almond
Frz Choc
ULT Choc
Chip
Chip
Cooky
Sheets
TO BE
NEW
DISCD
Vemag
Unifiller
Unifiller
Unifiller
Action
No change of die,or cleaning required
Change of die required
Wash Down
Wash Down and change of die required
change die and Push out dough yield loss
Change Machines to Vemag
Approx. required time (mins)
0
20
60
60
22
40
• Divider and mixer
changeover matrix was
created to be added into
the daily schedule.
• Sustainment: Update
cycle times. Add new
cookie types, as well as
remove discontinued
cookies. Update cycle
times for each machine.
• Future
Recommendations:
Update the commercial
dividing change over
matrix. Create more
detailed mixer change
over matrix.
Operations Management
• A mixing tracking sheet was developed for the operator to fill out to
investigate the deviations that exist between scheduled and actual
production at the mixer.
• A scheduling tool was created for the team leader to create a more
accurate daily schedule.
• This schedule can be updated throughout the day as production
plans change.
Operations Management
• Updated cycle times
• Sanitation
• Breaks
• Change over
Updated Engineering Requirements
Sub Shop Cookies (March 24-31)
1:00
0:50
0:40
0:30
0:20
0:10
0:00
C/T
1
2
3
4
5
6
Batch
7
8
9
10
11
12
Updated Engineering Requirements
Ultimate Cookies (March 28-29)
1:00
0:50
0:40
0:30
0:20
0:10
0:00
C/T
1
2
3
4
5
6
Batch
7
8
9
10
11
Operations Management
Sustainment:
• Update cycle times as well as
change over times
• Update sanitation times
• Train all team leaders
• Update scheduling tool
instructions
Future Recommendations:
• Incorporate mixer schedule
into the ROSS system
• Separate changeover time and
sanitation time
• Create similar tool for dividing
schedule
• Integrate dividing times to
create dividing schedule as
well
Mixing Prep Activities
• An experiment was conducted
to determine if an additional
mixer operator would
synchronize mixing and
dividing steps.
• Only high volume cookies were
analyzed.
• Adding an additional operator
to the Sub Shop cookies and
Sub Shop with Nuts cookies
will have a production increase
of 50% and 86%, respectively
(based on cost analysis).
Standard Work Implementation
• Standard work was created for
mixing top cookies for both
one operator and two
operators.
• This lists all best practices and
average cycle times for each
job element.
• This will help in training new
mixing operators as well as
improving current processes.
Updated Engineering Requirements
Mixing Prep / Standard Work
Sustainment:
• Update rates
• Update job element times
• Update standard work with
best practices
Future Recommendations:
• Test on other types of cookies
• Create standard work for all
cookies
Mixing Clean-Up Kaizen
Current Progress:
Future Recommendation:
• Interviewed Jim Roode about
• Map information flow
sanitation processes
• Agreed that sanitation can
work on a schedule
• Suggested ideal state would be
a one to two hour notice
• Sanitation employee will fill
out sanitation section of the
Mixer Operator Time Sheet
scenarios for mixer sanitation
• Collect data on sanitation cycle
time
• Update schedule to include
sanitation
Scaling Process Improvement
• Each recipe was updated to
include a full bags and partials
column.
• Reduces possible errors in
calculations and speeds up the
process of pre-scaling
• Helps in training new
operators
Scaling Process Improvement
Future Recommendation:
• Perform checks to ensure recipes are accurate.
Buyer Checks
Ingredient Size
When Ordering
Material Receiver
Performs Check as
Offloading
Ingredient Box
Material Handler
Performs Check as
Placing Box in
Inventory
Material Handler
Performs Check
when Picking
Ingredient Box
Operator Performs
Check when
Accepting Ingredient
Box
Positive Outcomes
• Better understanding of the current state of the production line.
• Provided tools that help with the decision making process on the
floor.
• Had weekly meetings with customer allowed everyone to always be
up to speed. Communication was the most important element of
project success.
• "Going to Gemba" was the best and most effective way to obtain
information.
• Had contingency plans for delays.
Project Improvement Areas
• Timing of the project can greatly impact analysis of current state
(i.e. seasonality).
• Align specific task with direct customer, this would facilitate
communication and proper implementation.
• Project scope should not be determined until the current state of the
system has been defined. Team needs to be prepared for scope
changes and scope creep with proper contingencies.
Future Recommendations
• Sustainment is just as important as making process changes and
improvements.
• Wegmans should have a kick off meeting at start of project (meet
operators, line leaders)
• Organizational Chart for people involved in project
• Responsibility matrix for project tasks (who to direct questions to)
• Better balance between defining process and implantation