Improvement Plan updates po

1. Improvement Plan updatespo Richard Latham Bridget Eggers Tyler Brent Valeria Gonzalez

2. 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

3. MSD I Summary

4. Project Plan – MSD II

5. Engineering Requirements

6. 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

7. 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

11. 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

12. 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)

13. 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

14. 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

15. 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)

16. 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

17. 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

18. Operations Management Divider • Current Progress: • Collect reasons for changeover • Next Steps: • Collect times for changeover • Create changeover matrix • Present matrix to scheduler

19. 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

20. Discussion