kaizen ideas

Defining steps to MSD IITYLER BRENTBRIDGET EGGERSVALERIA GONZALEZRICHARD LATHAMConcepts to KaizensStarted with conceptsKaizen activities include our conceptsProve feasibility and practicality of these conceptsSmall, resource constrained, fast implementationWe welcome feedbackSCALING A DAY IN THE PROCESS

Shares station w/ commercial.Cross-training evident.4 AM Commercial Pre-Scaler comes in.11 AM Frozen Pre-Scaler comes in.Multiple batches are pre-scaled at a time.Ingredients are stored in multiple locations.Work in process is not trackable.

SCALING KAIZENAdd labels to pre-scaled ingredientsSpeeds up communicationLess errorsModify cookies recipes format Less errors in scalingEasier for training.Checklist of whether ingredients are there before starting a batchPrepared if low on ingredientsCan change plan earlier

Add labels to pre-scaled ingredients

Reduce defects on scaling%INGREDIENTSSINGLEFULL BAGSPARTIALPROCEDURESSTAGE 121.76Brown Sugar8485379129Cream together for19.78Vream Rite Shortening271498504020 seconds0.61Salt2976372.202.20.61Baking Soda0722002.202.2STAGE 213.78Bessie Flour0848545010Add to above on high for10.2Am. Beauty Cake Flour520460370372 minutesSTAGE 35.09Liquid Whole Eggs07235218.5018.5Add to above on high for 3 minutes1.1Clear Vanilla Extract0427524040.28FB Soybean Oil(buckets)326108101STAGE 432.79Chocolate Chips-1000 ct088755116.67416.67Add to above on mixthoroughly on high for 1 min90 COOKIES PER CASE100TOTAL:360.57Cookie Pucks no NutsChecklist of whether ingredients are there before starting a batch

MIXING A DAY IN THE PROCESSShares with commercial.Deviation between types.Average cleaning time: 12 minutesLabor driven processAverage process time and Actual vs. Scheduled:

MIXING KAIZENHave all boxes opened before being placed beside the mixerFaster once on the mixerScale liquids (eggs, vanilla) ahead then store in pie roomFaster once on the mixerBreak down ingredient boxes after all mixing is completeReduces mixing cycle timesTracking sheet for mixerTracking improvement for systemMIXING KAIZENMixer schedule located by the mixerOther lines know when mixer is availableMaterial handler knows when materials are needed at the mixerAfter mixing, operator takes all unused ingredients away and checks schedule to see if any will be need for next productSpeeds up next productCan be done by other employeesAssign roles to material handler to collect and return ingredientsSpeeds up machine downtimeRelieves mixer operator of extra workHave mixer operator do sanitation on mixerReduce downtime for mixing changeovers

MIXING KAIZENGet a 3rd commercial troughLess downtime on mixerHave all ingredients put into one bucket so no box opening while on the mixerFaster once on the mixerDifferent boxes to receive ingredients in, easier to openFaster to open and break down

DIVIDING A DAY IN THE PROCESSShared with doughnuts, muffins, etc.Average actual run time:2 hrs and 33 minsStart time:Min 5:49 pmMax 8:14 pmAvg 6:52 pm

Average downtime:

DIVIDING KAIZENReassign roles for dividing staffReduces dividing downtimeChange type of wireWill break less oftenEnsure machine is setup on timeMaximize available time for dividingOne type of machine per dayChangeover time doesnt interact with operation time

SYSTEM A DAY IN THE PROCESS

Frozen Cookies

Commercial Cookies

SYSTEM-LEVEL KAIZEN (Methods)Update schedule with more accurate timesSchedule will reflect actual better.Add changeover time into scheduleSchedule will reflect actual better.Offset break schedules so another operator can run mixerincreased utilization of mixerAdd in breaks of workers into schedule if breaks cannot be offsetmore accurate scheduling and planning of resourcesStart commercial mixing earlier in the dayFrozen cookie mixing should have less late startsCreate standard workbest and fastest way, reduces variability

SYSTEM-LEVEL KAIZEN (Methods)Run commercial cookies with butter on a different day than frozen cookies with buttermore soft butter available, less nearby inventoryMix sheet cookies the night beforemore mixing time availableA way to know if there is enough time to do more batches for the nightget ahead for the next day, not run lateHave schedule of spiral 2 and commercial oven line up betterScheduled Production = Actual Production, Reduce variabilityMake communication boardEveryone knows what is going on.Improve tracking board for managementEveryone knows what is going on.

SYSTEM-LEVEL KAIZEN (man)Packaging workers come help with dividingDividing downtime reducedDivider workers come help with mixingMixing downtime reducedAdd more cross trainingFlexible staff to work different processes.

SYSTEM-LEVEL KAIZEN (machine) Fix frozen troughs and redesign to stop future problemsSafer and easier workflow