PROJECT STATUS UPDATEP10711 & P10712

Andreana Crance, Industrial & Systems EngineeringMatt Syska, Industrial & Systems Engineering

PROJECT STATUS UPDATE 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 OverviewThe 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 facilityStandardize procedures (i.e. changeovers, storage)Utilize workers’ time in a more efficient wayImprove overall efficiency of facility in order to make a greater profitImprove safety conditions for all workers

Primary Market /Project OpportunitiesWegmans central bakeshop and culinary innovation center in Rochester, NY

Secondary Market /Project OpportunitiesSimilar Wegmans production facilities

Stakeholders Wegmans Central Bakeshop and Culinary Innovation Center in Rochester, NYScott Young and Wegmans’ engineering groupBakery and Culinary workers whom are effected by the changesRaw Material and Ingredients ProvidersWegmans Distribution Center CommunityCommunity that purchases the products

PHASE 1: CONCEPT DEVELOPMENTIDENTIFY CUSTOMER NEEDS - INTERVIEWSPrimary Customer(s)

Wegmans Engineering TeamScott 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 LineAutomating a perviously all hands-on processP09712 – Commericial Roll Line Shrink ReductionDecrease amount of wasted rolls and improve effeciency of processP09713 – Bread and Roll Scaling RoomMake overall layout of room more efficient and effective for employees

PROJECT CONTEXT

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/Impr

ovement for Cookie Line

Fresh Bread and Roll

Scaling Room

Commercial Bread Line

Shrink Reduction

ERP Implementat

ion

Packaging Automation/Impr

ovement for Cookie Line

Fresh Bread and Roll

Scaling Room

Commercial Bread Line

Shrink Reduction

ERP

Implementation

CURRENT WORK P09711 – Cookie Line Automation

P09712 – Commercial Bread Line Shrink Reduction

P09713 – Fresh Bread and Roll Scaling Room

FUTURE WORK BASED ON CURRENT WORK

Re-evaluated projects defined in Fall 2008 DPM with Wegmans:

Packaging Automation/Impr

ovement for Cookie Line

Fresh Bread and Roll

Scaling Room

Commercial Bread Line

Shrink Reduction

ERP Implementat

ion

Ergonomics

Universal Rack System

Packaging Automation/Impr

ovement for Cookie Line

Fresh Bread and Roll

Scaling Room

Commercial Bread Line

Shrink Reduction

ERP

Implementation

Ergonomics

Universal Rack System

AFFINITY DIAGRAM –RAW DATA FROM CUSTOMERS AND STAKEHOLDERS

Lean

No Standardization

High Volume, High Mix of products

Batch Processing & Bulk Savings

Loading Procedures

Resource Usage

Scalable

OBJECTIVE TREE – WHY DOES THE CUSTOMER NEED THIS PRODUCT?

This Product or ProcessNeeds to …

Lean ProcessesImprove Loading

Procedures

Scalable solution

Proper utulization of

resoruces

SafetyEnsure safety

of workers

Stop problems before they

occur

Reduce current noise

issues

Material HandlingHandle variety

of materials

Improve storage of large

raw material

Transferrable

LayoutEffeciently 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

LeanReduce time to load and unload

machines

Able to be sized up due to high

demands

Perform to the bottleneck

SafetyPerform to the set standards

Be proactive in solving safety

problems – report any issues

Not bring noise levels above

acceptable standard

Material HandingHandle up to 2,000lbs of

material

Accessible and cost efficient

storage

Able to move facility to facility without failing

LayoutImprove flow of

goods and people

Effectivley use space in order to

allow for expansion

Be cost effective

PRELIMINARY IDEAS

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

FUTURE PLANWHERE DO YOU GO FROM HERE?

Action Date

Meet with faculty guide and tech lead to discuss possible projects

Week 6/7

Set up facility tour with Wegmans Contacts Week 6/7

Analyze Projects Week 7/8

Discuss Top Project Choices with Wegmans Week 8/9