P14712: Frozen Cookie Capacity Increase
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Improvement Projects

Table of Contents

Projects

This page describes the work done on each of the five improvement project categories:

Mixer Worker Justification Project

Initially, a preliminary checklist was drawn up for the project. Two experiments were conducted to test work instructions with two mixer operators on the Sub Shop variety cookies (with and without nuts) on 2/27/14 and on the Ultimate variety (without nuts) on 3/4/14.
Cycle time comparison between mixing operation with one and two workers

Cycle time comparison between mixing operation with one and two workers

Standard work was devised for how the work would be divided between the two workers for these cookie varieties. After one of the cookies that was going to be examined was discontinued, the final analysis was given to management on 4/8/14. Management to decide by 4/22/14 if two mixer operators will be used in practice for the two cookie varieties.

Throughput comparison between mixing operation and dividing operations with one and two workers

Throughput comparison between mixing operation and dividing operations with one and two workers

Sanitation Kaizen

A preliminary checklist was drawn up for this project. An interview with Jim Roode was conducted on 2/20/14 to summarize issues existing in the sanitation process for the Frozen Cookie Line.

The team aligned this improvement project with the Mixer Operator Time Sheet, which was used for data collection at the mixing step (see Operations Management project). The operator would write down when the sanitation team leader was called, when the sanitation worker was requested to arrive, and the sanitation worker would note what time they arrived and what time they had completed the sanitation of the mixer.

Sanitation part of 'Mixer Operator Time Sheet'

Sanitation part of 'Mixer Operator Time Sheet'

Unfortunately, due to some miscommunications with those involved in the data collection, the data wasn't collected properly for several weeks. On 4/18/14, the Sanitation Kaizen was shifted from an improvement project to a future recommendation that the RIT team would draft at the conclusion of the MSD project.

Recipe Modification Project

After observing the steps in pre-scaling and mixing, some waste was observed in how the worker calculated the needed ingredients for each batch. A simple solution was proposed regarding simplifying the recipe to remove a need for calculation. Wegmans management created an initial recipe change and after speaking with workers, management agreed to create more modified recipes on 4/8/14.

On 4/16/14, the remaining recipes for the Frozen Cookie products were sent to management. On 4/23/14, the decision was made by management to not deploy these changes. Here is an example of a recipe modification.

Example of new recipe that separates the ingredients into full bags and partial amounts

Example of new recipe that separates the ingredients into full bags and partial amounts

Operations Management

A preliminary checklist was drawn up for this project.

Mixer Operator Time Sheet

One of the main problems noticed on the Frozen Cookie Line was the inability to track the deviation between actual production flow and scheduled production. The Mixer was marked as a shared resource and in order to track the production flow, a form needed to be created to track not only the production flow of the Frozen Cookie Line, but also the Commercial Cookie Line throughout the day. The team then constructed a Mixer Operator Time Sheet for operators to track the time each product was in the mixer and any associated downtime in the process.
This form was explained to the commercial and frozen mixer operators on 2/24/14 by the RIT team (notes from the meeting). On 3/16/14, the clipboard for the tracking sheet was mounted adjacent to the mixer. A team leader sign off was added to perform daily checks on the form on 4/30 to ensure the data collected was properly checked. This data was collected for the remainder of the project.
Mixer Operator Time Sheet

Mixer Operator Time Sheet

Mixer Scheduling Tool

In order to appropriately investigate the deviations that exist between scheduled and actual production at the mixer, a tool was developed for the team leader to create a revised schedule. The Mixer Scheduling Tool uses Visual Basic for Applications (VBA) in Excel to automate the schedule making process. This new schedule breaks down each product type scheduled to be mixed into a form with the necessary batches and the expected cycle time for each batch. This tool was given to management on 4/17/14. A second version was sent on 5/19/14 that incorporated the Commercial Cookie Divider Changeover Matrix to account for changeover between commercial products (Mixer Scheduling Tool w/ C/O Matrix). Instructions for using the Mixer Scheduling Tool were provided. The Scheduling Tool was tested and implemented on the floor. The team leader found it helped understand better on how many batches to plan for the day and whether he was able to plan more or less for the day than originally anticipated. This scheduling application was to make more transparent the variability occurring from an operations standpoint on the line. If this temporary solution were to be continued, the recommendation would be to include the dividing cycle times into the plan so that the start and end time for the entire production of the line could be planned for. The future plan is for Scheduling to implement the features of this tool in their system to account for the sanitation and changeover times.
Mixer Scheduling Tool

Mixer Scheduling Tool

Output of Mixer Scheduling Tool

Output of Mixer Scheduling Tool

Management also requested a changeover matrix be developed for the Dividing process in the Frozen Cookie Line. The Frozen Cookie Divider Changeover Matrix was constructed and proposed to management on 4/1/14. And it was implemented in the weekly schedule sent to Operations starting week of 4/14/14.
Frozen Cookie Divider Changeover Matrix

Frozen Cookie Divider Changeover Matrix

Standard Work

At the request of the team leader, a Frozen Cookie Weight Check Sheet was created to keep the frozen cookie weight standard when dividing. This form was proposed to management on 2/18/14. It was implemented the same week.
Frozen Cookie Weight Check Sheet

Frozen Cookie Weight Check Sheet

Mixing Work Instructions

Work instruction of the mixing steps for two operators (see Mixer Worker Justification Project) was presented to management on 4/15/14 and 4/18/14. The final work instructions were presented to management on 4/29/14.
Example of Mixer Standard Work

Example of Mixer Standard Work

Management Standard Work

A method to analyze, as well as audit, the data collected using the Mixer Operator Time Sheet was necessary. A Cookie Mixing Process Control form was devised to interpret deviations that may exist between scheduled and actual production for specific products, as well as to visualize patterns in downtime. The form allows for multiple variables to be reported in order to determine where gaps exist for further root cause analysis. This standard work tool is to be pilot studied by Engineering before turning it over to Operations. It was presented to management on 4/21/14.
Cookie Mixing Process Control Sheet

Cookie Mixing Process Control Sheet


The initial test of this analysis tool allowed management to identify the deviations occurring between the scheduled production time and actual production time. This analysis tool serves to identify deviations in cycle times of different cookie varieties, changeover times between cookie varieties, and identify any other reasons for downtime and their occurrences. This analysis tool would then allow further root cause analysis on these deviations in order to continuously improve the mixing process. One identification made in the first use of this analysis was that there seems to be some unexpected downtime of the mixer in the early mornings that hadn't been accounted for in the schedule.

Progress Reviews


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