Seasonal Application o f MSW/PSW
32
Seasonal Application of MSW/PSW Ralcorp Frozen Bakery Products
description
Seasonal Application o f MSW/PSW. Ralcorp Frozen Bakery Products. Ogden, UT. Introduction to the Business. Seasonal Calendar. Ogden, UT. Size of property = 9 acres Main plant constructed in 1940’s (leased ). Produces packaged frozen cookies and waffles 12 finished production lines - PowerPoint PPT Presentation
Transcript of Seasonal Application o f MSW/PSW
Seasonal Applicationof MSW/PSW
Ralcorp Frozen Bakery Products
Ogden, UT
Introduction to theBusiness
Seasonal Calendar
Ogden, UT
• Produces packaged frozen cookies and waffles• 12 finished production lines
• 2-3 frosted sugar cookie lines• 4 rotary cut cookie lines• 2 wire cut cookie lines (Meincke)• 1 no-bake cookie line• 1 assembly line• 2 waffle lines:
•700+ SKUs•Theoretical capacity utilization Cookies = 62% (annualized)• Theoretical capacity utilization Griddle = 99%
• Size of property = 9 acres• Main plant constructed in 1940’s (leased)
Ogden, UT – Basic Layout
Ogden, UT
Line 1 - Ogden
Mix
er
Extruder Oven Enrobe Cooling Tunnel Package/PalletizeCell 1
Cell 2 Cell 3
Products:
Unique Features: Tri-Ex Process Enrobing
Ogden, UT
Line 2 - Ogden
Mix
er
Extruder Oven Enrobe Cooling Tunnel Package/PalletizeCell 1
Cell 2 Cell 3
Products:
Unique Features: Enrobing
Ogden, UT – Lines 1&2 Capacity
Assumptions Without prebuild.
Issues
Opportunity
Recommendation Prebuild Jun-Aug to smooth Sep-Nov
Ogden, UT – Lines 1&2 Capacity
Assumptions With prebuilds. Ramp up with everyday/harvest product production in June, Christmas in July
Issues
Opportunity Costco Meinke bar cookie – 18000cs
Recommendation
Ogden, UT
Line 5 - Ogden
Mixer Extruder Oven Frosting Cooling Tunnel Package/Palletize
Cell 1 Cell 2 Cell 3 Cell 4
FR. MIXPre Scale
Unique Features: Auto Tray Packer Auto Palletizing
Products:
Ogden, UT
Line 6 - Ogden
Mixer Extruder Oven Frosting Cooling Tunnel Package/Palletize
Cell 1 Cell 2 Cell 3 Cell 4
FR. MIXPre Scale
Unique Features: Wire-cut FSC’s Auto Palletizing
Products:
Ogden, UT
Line 8 - Ogden
Extruder Oven Frosting Cooling Tunnel Package/Palletize
Cell 2 Cell 3 Cell 4
Mix
er Cell 1
Unique Features: Wire-cut FSC’s Rotaries Trays Products:
Ogden, UT – Lines 5,6,&8 Capacity
Assumptions Demand without Holiday pre-builds
Issues
Opportunity
Recommendation
Ogden, UT – Lines 5,6,&8 Capacity
Assumptions Demand with Holiday pre-builds
Issues
Opportunity
Recommendation
Prior Process
Prior Process for MRP
Prior Process
• Excel-based, only using QAD as an input• Macro / VB driven• Many customized reports• Maintained by one individual• Burden to their system/network
Prior Process – Seasonal Tracker
Prior Process – Detailed Schedule
Prior Process – Component Sched
Prior Process – WO Reconciling
Why transition?
Why Transition?
Why transition?
• Excel process not supported• Cannot be upgraded easily• Corporate IT support near impossible• “Custom” to the plant and scheduler
• Standard of work• Community of users• Training available• Support within the company• Maintain QAD – value added
• More efficient• Workbench supported by IT, QAD• Regular patches and updates released• Less burden on the planners and systems
Project Charter
Planning Tool Decision• Outside Vendor• MSW/PSW (QAD)
Project Timeline• Overview• Available to Promise
Risks• Inputs• Solutions• Outputs
MSW/PSW versus Outside Vendor
Item MSW/PSW Outside Solution
Software/Implementation Already in QAD $100K+ per site plus yearly fees
Hardware cost Not needed Dedicated server needed per site
Training QAD/Logan/Two other plants Provider-based
Delivery time 3 months 6+ months
Complexity Integrated within QAD Programming Logic – complex setup – must bridge with QAD
Scheduling Create & Optimize within MSW/PSW. Manages schedule exceptions.
Still requires up-front work orders. Schedule optimizer.
Utilization Any plant as needed “One off” for Ogden – other plants lack the needed complexity
Ogden MRP Timeline
2013 (weeks)1/28 2/4 2/11 2/18 2/25 3/4 3/11 3/18 3/25 4/1 4/8 4/15 4/22 4/29 5/6
Charter Presentation/SignoffINPUTS• Forecasting• MRP Parameters• MSW Parameters/SetupAPP TESTING & TRAINING• Available to Promise Test/Train• MSW/PSW Test/Train LiveOUTPUTS• Master Schedule Test Live• Detail Schedule Test Live• Shop Floor Documents Develop Test Live• Component Availability Test Live
• CUTOVER / GO LIVE Parallel Live
• SUPPORT
Risks
OutputsComponent Availability Check•BOM Accuracy
ATP Data•Must account for freeze time (modification)
Change Mgmt.•Plant buy in•Address concerns
KPI’s• Impact to CFR, DOH
ApplicationsATP Project•Business agreement•Deliverable?
MSW/PSW•Minimal experience in frozen
Workbook•No support•No off switch
InputsForecast•Accuracy•Consumption Logic
Inventory•Accuracy
Planning Parameters•“Dialing In”•New products
Distribution Orders•Timing
Custom Reports
Custom Reports
From this…
From this…
To this.
End result…
