IMPROVEMENT
PLAN UPDATESPO
Richard Latham
Bridget Eggers
Tyler Brent
Valeria Gonzalez
PRESENTATION OBJECTIVES
 Summarize what was achieved last semester
 Present project timeline
 Updates on activities
 Mixing Prep Activities
 Mixing Clean Up Kaizen
 Scaling Process Improvement
 Operations Management
 Standard Work Implementation
MSD I SUMMARY
PROJECT PLAN – MSD II
ENGINEERING REQUIREMENTS
MIXER WORKER JUSTIFICATION PROJECT
 Objective:
To make a decision about whether a second operator is justifiable in the frozen cookie
mixer process (for cookies with inclusions).
 Engineering Requirements:
 Characterization of all process steps
 Throughput
 Implemented solutions are consistent across all crews and shifts
 Tools that make system run smoothly
 Management approval
 Test Method:
 Cycle time improvement
MIXER WORKER JUSTIFICATION PROJECT
 Current Progress:
 Videos taken for Dads, Ultimate w/ nuts, Sub Shop w/ nuts
 Process analysis completed for one operator
 Job elements created for two workers based off reasonable assumptions
 Job element comparison charts created for one worker vs two workers
1 operator
2 operators
Dads
26 min 15 sec
15 min 9 sec
73% increase
1 operator
2 operators
Sub Shop W/ Nuts
33 min 34 sec
17 min 38 sec
90% increase
1 operator
2 operators
Ultimate W/ Nuts
27 min 50 sec
16 min 8 sec
72% increase
MIXER WORKER JUSTIFICATION PROJECT
 Next Steps:
 Experiment with two workers
 Create standard job element sheet for two workers using operator feedback
 Present findings to management
SANITATION KAIZEN
 Objective:
Create a system that allows the sanitation employee to be at the mixer at the right time.
 Engineering Requirements:
 No food safety, ergonomics, quality impacts
 Throughput
 Characterization of all process steps
 Implemented solutions are consistent across crews and shifts
 Tools that make system run smoothly
 Management approval
 Test Method:
 Mixer wait time per week (see Mixer Operator Time Sheet)
SANITATION KAIZEN
 Current Progress:
 Interviewed Jim Roode about 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
 Next Steps:
 Map information flow scenarios for mixer sanitation
 Collect data on sanitation cycle time
 Update schedule to include sanitation
 Present findings to management
RECIPE MODIFICATION PROJECT
 Objective:
Increase usability of recipe by removing the need for calculations to find the number of
bags/boxes needed.
 Engineering Requirements:
 Characterization of all process steps
 Implemented solutions are consistent across crews and shifts
 Tools that make system run smoothly
 Sustainable solution methods
 Management approval
 Test Method:
 Does the sheets make sense to the operator? - Yes/No
 Are the sheets being utilized regularly? - Weekly Team Leader Audit
OPERATIONS MANAGEMENT MIXING
 Objective:
Make mixer its own resource and develop a single daily mixer schedule.
 Engineering Requirements:
 Characterization of all process steps
 Tools that make system run smoothly
 Implemented solutions are consistent across crews and shifts
 Management approval
 Test Method:
 Planned vs Actual number of batches (see Mixer Operator Time Sheet)
OPERATIONS MANAGEMENT MIXER
 Current Progress:
 Collecting mixer cycle times for frozen and
commercial cookies
 Created preliminary mixing schedule
 Down time, reason, sanitation
 Trained mixer operators on mixer tracking sheet
 Next Steps:
 Collaborate with frozen and commercial schedulers
on mixer schedule
 Test and validate schedule
OPERATIONS MANAGEMENT DIVIDER
 Objective:
Create changeover matrix for divider for use in scheduling.
 Engineering Requirements:
 Characterization of all process steps
 Tools that make system run smoothly
 Implemented solutions are consistent across crews and shifts
 Management approval
 Test Method:
 Was changeover time accounted for in the weekly schedule? – Yes/ No
 Does the matrix clearly provide the changeover time between different cookie
types? - Yes/No
OPERATIONS MANAGEMENT DIVIDER
 Current Progress:
 Collect reasons for changeover
 Next Steps:
 Collect times for changeover
 Create changeover matrix
Frozen Cookies Changeover Matrix (Time to change)
To
 Present matrix to scheduler
Products
125303
197668
From
58940
372378
379705
357632
Sub Shop Cookie Pucksw nuts
W/Nuts
Cookie PucksSub Shop
No Nuts
Frz Choc Chip
Dads old
Cooky
way
TO BE DISCD
ULT Choc Chip
Dads
Sheets
new way
NEW
Frz Ult ChChp
Ultimate
Cooki 1.1oz
Ultimate Frz Ult ChChp
w nuts
Nuts 1.1oz
Frz Chc Chc
Chunk Cky 1.1
Machine
W/U
W/U
W/U
W/U
W/U
W/U
W/U
125303 197668
58940
372378
379705
Sub Shop
Dads old
Dads
Ultimate
Sub Shop
Ultimate
w nuts
way
new way
w nuts
Frz Choc
ULT Choc Frz Ult
Cookie Cookie
Chip
Frz Ult
Chip
ChChp
Pucks- Pucks-No Cooky
ChChp
Sheets
Cooki
W/Nuts
Nuts
TO BE
Nuts 1.1oz
NEW
1.1oz
DISCD
357632
Frz Chc
Chc
Chunk
Cky 1.1
x
x
x
x
x
x
x
313034
126403
282062
Frz
Frz Pnut
Frz
Oatmeal
Btr
Snickerd
Raisin
Cookie
oodle
1.1oz
1.1oz
Pucks
STANDARD WORK IMPLEMENTATION
 Objective:
Create work instructions for revised process improvements
 Engineering Requirements:
 Characterization of all process steps
 Implemented solutions are consistent across crews and shifts
 Tools that make system run smoothly
 Sustainable solution methods
 Management approval
 Test Method:
 Do the updated work instructions make sense to the worker? – Yes/No
 Are they being utilized regularly? – Weekly Team Leader Audit
DISCUSSION