P09712Commercial Roll Line Shrink Reduction

Evan DeCotis Levi Stuck Ryan Dennison Joseph Fitzery Cinthia Sanchez

Financial Benefit

Annual Defect Cost = $321,000

40% Defect Reduction

$129,000 Annual Savings!

Project Review Agenda

Project Overview

Customer Needs and Project Specifications

Concept Development

Systems Level and Detailed Design

Risk Mitigation

MSDII Plan

Financial Benefits

High Priority Customer Needs

Importance Customer Need (Description) Comments / Status

  Eliminate Shrink/Waste

 

9 Defects 5-10% current defect rate

9 Standardization of ProcessCurrently there is minimal

standardization at the bakery

9 Minimal Cost Do not exceed $5,000

9=Very Important, 3=Important, 1=Somewhat Important

*Simplified version - only high importance items are shown

Engineering Specifications

Importance Specification (Description)Unit of

MeasureMarginal

ValueIdeal Value

Comments / Status

9 Defect rate reduction % > 20% > 60%  

9Defect occurrence area categorization

# >= 2 >= 5K-roll, Proof Box, Oven, Conveyor,

Bagging

9 Defects type categorization # >= 4 >= 6

Rolls not grouped, fingerprints in

dough, dry spots, etc.

9Standard work procedures can be learned in X minutes

Minutes < 45 < 15

Minimal time lost due to any necessary retraining

3 Process time variation Minute range 10 to 20 0 to 10  

3 Visual aid interpretation Seconds <5 <1Time will reduce from exposure

1 No capital investment USD <= $5,000 <= $1,000  

9=Very Important, 3=Important,1=Somewhat Important        

Current State Value Stream Map

Cause and Effect

DEFECTS

PEOPLE

Daily Bias (Inconsistency)

Lack of Thoroughness

Lack of United Goals

Material Handling

INFORMATION

Isolated Information

Often does not Leave the Station

Lack of Formal Training

Lack of Formalized Data

ENVIRONMENT

Noise Level

Variance in Humidity

Variance in Temperature

PROCESSES

Line Imbalance

Standard Work

High Variation

Reactive Vs. Proactive

MACHINES MATERIAL

Outdated

Adjustability (Analog vs. Digital)Inconsiste

nt

Lack of Fine Tuning

External Contaminants

Inconsistent Dough Mixtures

Upgradable

Data Collection

354

82

950

1015

75

743

Hamburger Rolls - 7.5% Defect Rate

Broken

Bubble

Disfigured

Dryspots

Indent

Misaligned

Oil Mark

Overcooked

Over Floured

Thumb Print

Undercooked

Data Collection

7

34

76

28

21

10

12

18

166

Hot Dog Rolls - 4% Defect Rate

4+4BrokenBubbleDisfiguredDryspotsMisalignedOil MarkOvercookedOver FlouredThumb PrintIndent

Data Collection

4+4

Broken

Bubble

Disfigure

d

Dryspots

Indent

Misa

ligned

Oil Mark

Overcooked

Over Floure

d

Thumb Print

Undercooked

Not Reco

rded

0

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

7

34

76

2821

10 1218 16

635 4 82 950 10 15 75 7 43

Hotdog Rolls and Hamburger Rolls Defects

Hamburger Rolls Hotdog Rolls

Defect Type

Qty

(1 =

4 b

uns)

70%

Current State Value Stream Map

K-Roll Process Improvement

Proposal Run the K-rolls at a rate equal to, or less than

the rate of the oven at all times

Visible Problems Queuing before and after Proof Box Inconsistent bake times and proof times

Ideal Proof Box Time – 50 minutes One K-roll Running – 55 min proof with 3% - 5%

defective Two K-rolls Running – 75 min proof with 10% - 12%

defective

Line Imbalance

10

1000

2000

3000

4000

5000

6000

7000

8000

9000

10000

Oven

K-roll 2

K-roll 1

# R

olls

pe

r H

r

Roll Production vs. Oven Capacity

K-R

oll 1

K-R

oll 2

K-Roll Output Oven Capacity

Implementation

Develop a standardized K-roll procedure Conduct training on procedure use Develop test plan to verify improvements *Establish performance management*

Impact No queues before or after Proof Box 30% estimated reduction in defects

Proof Box Process Improvement

Proposal Standardized rack loading and unloading

procedure Track times of racks through the Proof Box

Visible Problems Inconsistent rack loading/unloading Uncooked buns left outside of proof box for

long periods of time No current standardized procedures

Proof Box Process Improvement Process standardization Time tracking Optimal batch sizes Reduced non-controlled environment time

Implementation

Develop a standardized Proof Box procedure Conduct training on procedure use Develop test plan to verify improvements *Establish performance management*

Impact No queues during oven loading 10% estimated reduction in defects

Additional Benefits Mindset of standardized work will be instilled for future

improvements

Quality Control Process Improvement

Proposal Improve defect sorting accuracy by creating visual

aids Create a QC training manual for all employees

Visible Problems Lack of consistency in defect classification Some defects get through QC and sent to

customers Some good products are rejected as defects

Quality Control Process Improvement

Implementation

Develop a standardized QC procedure Construct two laminated “on floor” poster size

visual aid stands Construct a fully usable training manual Develop test plan to verify improvements in sorting *Establish performance management*

Impact Clarified/unified defect sorting and categorization Reduction in type I and type II errors

Risk Mitigation

Proc. # Risk Severity Probability Mitigation

1,2 No employee buy-in 9 7Employee involvement, feedback, and performance management

1,2No long-term consistency and commitment

9 5In house project responsibility, performance management

1,2 Implementation delay 9 3 Adequate Planning

2Workers may not use visual aids

9 7 Performance management

Importance: 9=Very Important, 3=Important, 1=Somewhat Important

*Simplified Version, only high severity risks shown.

Financial Benefit

Regular Hamburg RollsRegular Hotdog Rolls

Lite Hotdog RollNew Eng 6pk  Rolls

Wheat Hamburg RollPlain Italiano Roll

Potato Hamburg RollPotato Hotdog rollWheat Hotdog RollLite Hamburg RollPlain Dinner Rolls

Bake N Serve Plain  RollsPlain Soft Sand RollsSeeded Italiano Roll

12pk New England RollsSeeded Soft Sand RollSeeded Sandwich Roll

White Sand RollWheat Sand Roll

Wheat New England RollsPotato Sand Roll

Sesame Dinner RollsWheat Italiano Roll

Bake N Serve Sesame RollsMultigrain Dinner Rolls

 $-   $15,000   $30,000   $45,000   $60,000   $75,000   $90,000 

Overhead Costs by Roll Type

$0.66/roll production costs

6% defect rate

40% of total defect costs = $129,000

Questions or comments?

Appendix I: Data Collection Hamburger Hotdog

Broken 31 2.54

Disfigured 75 6.14

Dry 853 69.86Misaligned

Oil Mark 9 0.74

Over Floured 66 5.41

Thumb Print 6 0.49Undercooked 38 3.11Not Recorded 143 11.71

Total Rolls 7,631

Total Defects 1,221

Overall Defects 7.41%

12% and 10% defect days with 2 K- rolls running!3% and 5.5% defect days with 1 K- roll

Defect TypeTotal Qty

(1=4 buns)% of total

Broken 28 12.28Disfigured 69 30.26

Dry 33 14.47

Misaligned 23 10.09

Oil Mark 8 3.51

Over Floured 15 6.58

Thumb Print 13 5.70

Undercooked

Not Recorded 39 17.11

Total Rolls 2,959

Total Defects 228

Overall Defects 3.71%

Defect TypeTotal Qty

(1=4 buns)% of total