Process Innovation Project Lessons
- Direct contact with the responsible party for each
specific part of the project is cardinal in setting clear
expectations and identifying the current state of the
system from their perspective.
- A client kick-off meeting would be useful for making
introductions to the relevant people and sharing contact
- Timing of the whole project can greatly impact
analysis of current state, with regard to seasonality.
- Conducting tasks across multiple departments can
present various issues with communication and
- It is important to bridge the information gap between
floor level managers and front office level managers.
- Sustainment is just as important as making process
changes and improvements.
- "Going to Gemba" is the best and most effective way
to obtain information.
- Have to expect and plan contingencies for customer
Project Management Lessons
- It is important to identify one person who is
ultimately responsible for a given task or problem.
- Communication is the most important element of
- Let the data do the talking when trying to prove a
point or illustrate an example.
- Need to be prepared for scope changes and scope creep
with proper contingencies.
Linking Finished Goods Inventory to Operations Scorecard
Currently, inventory is held in warehouses outside of
the Wegmans Bakeshop. This inventory can dissipate or build
without being communicated directly to those manufacturing
the product. A suggestion would be to include inventory in
the Production Operations Scorecard and extend
accountability for the finished goods inventory to
Extending the Recipe Modification Project (see
other areas of the BakeShop. Adding mistake proofing
element to the standard work would allow for the
calculation of ingredients throughout the facility during
the scaling operations to be eliminated or minimized by
employing a table of calculations to remove that extra
Continuing the Sanitation Kaizen (see Improvement Projects
performing analysis on the variability associated with
mixing and dividing sanitation processes would be useful. A
strong gap between the current state of sanitation on the
frozen cookie line and an ideal state is the ability to
reduce the large variability that exists in the cycle time
of cleaning the divider machine and blast freezer conveyor.
In observing the operations of the team leaders, the
team noted that there was communication gaps between one
team leader and a later team leader. Despite there being
hand-off notes from team leader to team leader, decisions
made earlier in the day can sometimes be misconstrued by
the end of the day. The team recommends the use of
communication boards to organize this communication in a
structured manner. This communication board can include an
assortment of useful information including worker
schedules, production and schedule changes, tracking of key
performance indicators on the line, and updates on current
projects on the line. These boards should have well defined
areas for each of these communication categories.
MSD I: Planning &
Execution | Problem Definition |
Systems Design | Sub-System Design |
MSD II: Test Plan | Improvement Projects |
Final Deliverables |