P13711: Wegmans Dough Mixing Process Improvement
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Systems Design

Table of Contents

During the systems design phase we observed the mixing process for over 20 hours to help identify the largest areas of opportunity. Before doing so we needed to understand the problem. Many tools were used to help assist in better laying out the customer needs and specifications prior making recommendations on solutions. These tools included a function decomposition, systems architecture, risk assessment, pugh charts, fishbone diagrams, and more.

Our final systems design presentation can be viewed here: System Design Review Presentation

Process of Refining Project Scope

MSD I Project Scope Revisions

MSD I Project Scope Revisions

Concept Development (generation, improvement, selection)

Fishbone Diagram

Fishbone Diagram

Functional Decomposition

Functional Decomposition

Functional Decomposition

This Functional Decomposition of the process shows the main problem area, Visibility, and ways to alleviate the problem. The possible ways to increase visibility on the floor include collection of real time data, signaling employees of next steps in the process, signal mechanical issues to employees, and signaling end of batches for decreased time lost to guessing. Each issue breaks down into its components to form the above Functional Decomposition

Floor Layout

Existing Production Floor Layout

Existing Production Floor Layout

Risk Assessment

The Risk Assessment is used to identify problems and help us determine a path to take to avoid it. Also, it helps us determine which problem is most likely to occur and the severity of the problem which represents the problems we need to be most concerned with. Please see the Detailed Design Section for the updated Risk Assessment

Pugh Charts

Recording Data Pugh Chart

Recording Data Pugh Chart

Data Representation Pugh Chart

Data Representation Pugh Chart

Systems Design Review

Presentation, notes, actions

System Design Review Presentation

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