kaizen ideas

Detailed design reviewTYLER BRENTBRIDGET EGGERSVALERIA GONZALEZRICHARD LATHAMValeria 1Presentation objectivesProject updateDecide on process improvement activities for Senior Design II Our goal is to obtain approval for all of the proposed activities and for you to suggest additional solutions Please ask questions about our proposed solutions to minimize future risks

Valeria 2Frozen cookie production Increase Pre Scale

MixStageDividePaper CutX-RayBlast FreezeMetal DetectPackageClose boxFreezer to ShipValeria3A DAY IN THE PROCESS

Frozen Cookies

Commercial Cookies

Valeria 4Problem Definition Current stateHigh variability in and around the production lineThere is a bottleneck at mixingUnderutilization of resourcesStaffing issuesNeed for overtimeLack of standardizationProduction delays

Target state Establish synchronized flow between scaling, mixing, dividing, and packaging steps Increase production capacity Maximize resources utilization Reduce/Eliminate the need for overtimeImplement standardized work Establish schedule flexibility Track and sustain production system

Valeria5Project status Started with customer needs and engineering requirements Observed and collected data Brainstormed on possible solutions/concepts based on collected dataCreated kaizen activities which include feasible concepts Prioritized and grouped kaizen activities Created detailed description of kaizen events Prove feasibility and practicality of these conceptsAssess and refine solutions Recommend solutions to customer Senior Design II Valeria6Customer needs & Eng. Requirements

Engineering MetricsScoreEngineering RequirementMeasure of PerformanceIdeal ValueMarginal Value27Food safety risksRate of occurences0018Ergonomic impactsErgonomic Study, Before/After0036Quality impactsRate of occurences0072ThroughputProduction efficiency percentage100% +/- 0%90% +/- 10%57Characterization of all process stepsVariability and production efficiency percentage100%85%21Manufacturing Manager, Bakeshop Production Area Manager, Manufacturing Engineer, Line Team Leader and Production Line Workers agree with proposed solutions.Evaluation checklistAll agreeAll agree18Implemented solution are consistent across crews and shifts.Binary (yes/no)YesYes27Tools that make system run smoothly.Current vs. Future productivity rate20% inc mixer 10% inc divider10% inc mixer 5% inc divider39Sustainable solution methods.Evaluation checklistAll agreeAll agreeValeria7Concept selection CategoryConcept NameLimited Resources ConceptNew Mixer ConceptNew Trough ConceptQuick Fix ConceptSustainable ConceptShared Stations Across Lines ConceptMachineBuy a new mixerxBuy an automatic scalexBuy new commercial cookies troughs xBuy new frozen cookies troughsxModify frozen cookies troughs xxFix frozen cookies troughs xxUse mixers from other lines/processesxxMan PowerAdd additional workersxxxCross-train employees xxxMaterial Increase storage area next to the scaling station xxxModify where ingredients are storedxxMethods/Procedures Modify scaling procedures to be more ergonomicxxModify mixing procedure to be more ergonomic xxMixing same types of commercial and frozen cookie dough at the same timexImplement lifting assistance for scaling/mixing proceduresxxCreate work instructions for line proceduresxxxxImprove ergonomics on the transportation of prescaling ingredientsxxxScheduling/communication board to display daily planned schedulexxxImplement visual aids to promote trough organization xxModify production line layout xxxSchedulingSet a standard schedule for ingredient preparation xxxSet a standard schedule for Pre-ScalingxxxxSet a standard schedule for MixingxxxxSet a standard schedule for Machine SetupsxxxSet a standard schedule for sanitationxxxStart frozen cookie prescaling earlier in the dayxxxStart commercial cookie mixing earlierxxxSchedule cookies to make in large quantity batches/less setups xxxxMix dough the day before xxxModify employees' schedule (1 hr)xxxxSimulationx x

x

x Valeria8Process Improvement priority matrix Cost Time Effectiveness Difficulty 1-Cheapest 1- Shortest1-Best 1-Easiest AverageSCALING PROCESS IMPROVEMENT 2.33Add labels to pre-scaled ingredients11313Modify cookies recipes format11212Checklist of whether ingredients are there before starting a batch11212MIXING PREP ACTIVITIES KAIZEN4.67Have all boxes opened before being placed beside the mixer12214Scale liquids (eggs, vanilla) ahead then store in pie room11212Standardize material handling roles12228MIXING CLEAN UP KAIZEN5.50Break down ingredient boxes after all mixing is complete12214After mixing, operator takes all unused ingredients away and checks schedule to see if any will be needed for next product12228Standardize material handling roles12228Have mixer operator do sanitation on mixer 11212DIVIDING PROCESS KAIZEN14.67Change type of wire232336Ensure machine is setup on time12214One type of machine per day11224OPERATIONS MANAGEMENT 8.00Update schedule with more accurate times122312Add changeover time into schedule12228Offset break schedules so another operator can run mixer12214Add in breaks of workers into schedule if breaks cannot be offset12214A way to know if there is enough time to do more batches for the night12228Have schedule of spiral 2 and commercial oven line up better132318Mixer schedule located by the mixer11212LABOR MANAGEMENT IMPROVEMENT 18.00Reassess task responsibilities132212Add more cross training232224STANDARD WORK IMPLEMENTATION 12.00Improve communication board for people on the floor 123212Improve communication board for management123212Improve work instructions 122312Valeria9SCALING Process current state

Shares station w/ commercial.Cross-training evident.4 AM Commercial Pre-Scaler comes in.11 AM Frozen Mixer comes in.Multiple batches are pre-scaled at a time.Ingredients are stored in multiple locations.Work in process is not traceable.

Bridget 10SCALING Process IMPROVEMENT

Bridget 11Add labels to pre-scaled ingredients

Bridget 12SCALING Process IMPROVEMENT

Bridget13Reduce defects on scaling%INGREDIENTSSINGLEFULL BAGSPARTIALPROCEDURESSTAGE 121.76Brown Sugar8485379129Cream together for19.78Vream Rite Shortening271498504020 seconds0.61Salt2976372.202.20.61Baking Soda0722002.202.2STAGE 213.78Bessie Flour0848545010Add to above on high for10.2Am. Beauty Cake Flour520460370372 minutesSTAGE 35.09Liquid Whole Eggs07235218.5018.5Add to above on high for 3 minutes1.1Clear Vanilla Extract0427524040.28FB Soybean Oil(buckets)326108101STAGE 432.79Chocolate Chips-1000 ct088755116.67416.67Add to above on mixthoroughly on high for 1 min90 COOKIES PER CASE100TOTAL:360.57Cookie Pucks no NutsBridget14SCALING Process IMPROVEMENT

bridget15Checklist of whether ingredients are there before starting a batch

Bridget16MIXING PROCESS CURRENT STATE Shares with commercial.Deviation between types.Average cleaning time: 12 minutesLabor driven processActual vs. Scheduled average process time:

Tyler 17Value added vs. non value added TimeCumulative TimeTask TimeTask14:150:00:0014:200:05:020:05:02Setting up stationNVA14:250:05:200:00:18Add ingredient VA14:250:05:280:00:08Walk/Open/FoldNVA14:250:05:380:00:10Add ingredient VA14:250:05:420:00:04Walk/Open/FoldNVA14:250:05:550:00:13Add ingredient VA14:260:06:050:00:10Walk/Open/FoldNVA14:260:06:400:00:35Add ingredient VA14:270:07:510:01:11MixVA14:310:11:520:05:12Grab more ingredientsNVA14:330:13:140:01:22Add ingredient VA14:340:14:050:00:51Walk/Open/FoldNVA14:340:14:120:00:07Add ingredient VA14:340:14:220:00:10Walk/Open/FoldNVA14:340:14:290:00:07Add ingredient VA14:340:14:540:00:25Walk/Open/FoldNVA14:350:15:010:00:07Add ingredient VA14:350:15:090:00:08Walk/Open/FoldNVA14:350:15:210:00:12Add ingredient VA14:390:19:200:04:11MixVA14:390:19:450:04:24Grab more ingredientsNVA14:400:19:580:00:13Add ingredient VA14:400:20:040:00:06Walk/Open/FoldNVA14:400:20:220:00:18Add ingredient VA14:400:20:290:00:07Walk/Open/FoldNVA14:400:20:470:00:18Add ingredient VA14:400:20:520:00:05Walk/Open/FoldNVA14:410:21:000:00:08Add ingredient VA14:410:21:070:00:07Walk/Open/FoldNVA14:410:21:190:00:12Add ingredient VA14:420:22:400:01:21MixVA14:440:24:530:02:13Dump doughNVA14:470:27:070:02:14Move troughs, cover and label them NVAPercentage of VA vs. NVA per observation12345Average VA0.40750.41300.57930.58430.59420.5157NVA0.59250.58700.42070.41570.42200.4876Tyler 18

Breakdown of mixing process time 19MIXING PREP ACTIVITIES KAIZEN

Tyler 20MIXING PREP ACTIVITIES KAIZEN

Richard21MIXING PREP ACTIVITIES KAIZEN

Should production be stopped if material handler is not available? (Mistake proof)Richard 22MIXING CLEAN UP KAIZEN

Richard 23DIVIDING process current state Shared with doughnuts, muffins, etc.Average actual run time:2 hrs and 33 minsStart time:Min 5:49 pmMax 8:14 pmAvg 6:52 pm

Richard 24Average downtime:Production CapacityBroken Wire0.70 %Paper Change0.39 %Machine Broke Down2.94 %Machine not set up0.50 %Total =4.54 %Richard25

Richard26DIVIDING PROCESS KAIZEN

Richard27System level approach

Frozen Cookies

Commercial Cookies

Valeria 28Operations management

Valeria 29LABOR MANAGEMENT Improvement

Tyler30Waste reduction through standard work

Tyler31Risk #Risk ItemCauseEffectLikelihoodSeverityImportanceAction to Minimize RiskOwner1Communication with Stake holdersLack of updates from team members, not attentive with emails/callsDelay in progress/scope creep236Maintain regular meetings and frequent status updatesGroup/Wegmans Management3Cookies not made on planned scheduleCommercial line impacts scheduleDelay in progress326Contact Wegmans management before visiting facilityGroup7Communication among team membersNot being attentive to emails/phone/textDelay in progress236Maintain regular meetings and communication via email/text/phoneGroup8Time constraintNot consistently working on project throughout the yearProject not completed236Continually working on project throughout the year/evenly distributing work among team membersGroup11Not being able to observe enough of the frozen cookie lineScheduling conflictsMissing information/misinterpretation of process236Split observations across group members to cover more production timeGroup13Need to redefine scope of projectOverall problems exist outside of frozen cookie lineDelay in progress236Perform Value Stream Map early and understand how outside systems effect frozen cookie dough line.Group/Wegmans Management14Outdated times/product information usedProvided information isn't validatedProject ineffective236Collect own data to understand the accuracy/relevance of old data.Group27Kaizen improvements don't cause significant production increaseNo change in production after implementationProject Unsuccessful236Ensure proposed kaizens are necessary and impactfulGroup26No Kaizen Events are approved by managementManagement doesn't agree with team's findingsDelay in progress224Provide iterative review process for management to screen kaizen ideasGroupRisk analysisBrainstormed 27 possible risks for this project, assessed the likelihood of happening, the impact to the project, and ranked them by importance level.8 more risks became critical since the beginning of the project

Tyler 32Project management tools

Tyler 33Discussion

34Kaizen PlanEvent Plan (Current and future state, and gap)Event Description (work center, performance measure to be focused on)Add labels to pre-scaled ingredientsThis is not a kaizen, this is a project. We will put together after asking if people on the floor agree, then will show the workers how it works and test the idea.Event Dates and TimesPreliminary Objectives20 minutes to explain labelsAdd labels to the scaled ingredient buckets to standardize the pre scaling process to eliminate errors and wait time. Creates a visual aid in order to see where the pre scaling process is at and what needs to be done next.test for a week, then decideCurrent Process (flow chart)Currently there are no labels on pre scaled ingredients. This leaves the possibility for errors and lacks important communication. If a worker leaves for break the helper can not easily pick up where they left off as they are not sure what has been scaled.TeamCurrent Situation and ProblemsLeader:RIT TeamCurrently a worker fills a container of pre scaled ingredients, yet there is no documentation of how many pounds or what ingredients have been added so far. This makes it hard to tell what is there and what still needs to be done. It also is hard for a second worker to fill in on breaks as they are unsure of where the process is it.Co-leaderFacilitatorBridget EggersSenseiManagersFloor personnelNoneStaff personnelNoneProduction IncreaseOutside EyesReduce errors to zeroIncrease communicationResources on call:

Kaizen Plan (2)Event Plan (Current and future state, and gap)Event Description (work center, performance measure to be focused on)Modify cookies recipes formatThis is not a kaizen this is a project we will put together after asking if people on the floor agree, then will show the workers how it works and test the idea.Event Dates and TimesPreliminary Objectives20 minutes to explain recipeModify the cookie recipes to eliminate the math required to find the number of pounds that must be pre scaled and the number of full bags needed.test for a week, then decideCurrent Process (flow chart)TeamCurrent Situation and ProblemsLeaderCurrently the recipes cards have the total pounds needed for each ingredient. The pre scaler worker must take out a calculator and divide out the fill number of bags needed and then take the remainder and pre scale into a separate bucket. This leaves a laCo-leaderFacilitatorSenseiManagersFloor personnelStaff personnelProduction IncreaseOutside EyesIncrease in pre scaling total available time of 5 minutesReduce errorsResources on call:BAKESHOP FORMULAITEM:Cookie Pucks no Nuts-#197668DATE:11/10/13%INGREDIENTSSINGLE(lbs)FUL BAGSPARTIAL(lbs)Triple(lbs)FUL BAGSPARTIAL(lbs)PROCEDURESSTAGE 121.76Brown Sugar8485379129237437Cream together for19.78Vream Rite Shortening27149850201506020 seconds0.61Salt2976372.202.26.606.60.61Baking Soda0722002.202.26.606.6STAGE 213.78Bessie Flour084854501015030Add to above on high for10.2Am. Beauty Cake Flour520460370371112112 minutesSTAGE 35.09Liquid Whole Eggs07235218.5018.555.5055.5Add to above on high for 3 minutes1.1Clear Vanilla Extract042752404120120.28FB Soybean Oil(buckets)326108101303STAGE 432.79Chocolate Chips-1000 ct088755116.67416.67350.01140Add to above on mixthoroughly on high for 1 min90 COOKIES PER CASE100TOTAL:360.571081.71

Kaizen Plan (3)Event Plan (Current and future state, and gap)Event Description (work center, performance measure to be focused on)Checklist of whether ingredients are there before starting a batchThis is not a kaizen this is a project we will put together after asking if people on the floor agree, then will show the workers how it works and test the idea.Event Dates and TimesPreliminary Objectives20 minutes to explain checklistMake a checklist of all the ingredients that will be needed for the day so that the worker can check that they are all there before starting on the job. This will reduce wasted time in pre scaling out ingredients used if all ingredients for the batch aretest for a week, then decideCurrent Process (flow chart)ScheduleType, # batchesrealize that there are not enough chocolate chipsCollect some ingredientschange to different type of cookiespre scale out ingredientsmust re start pre scalingMixTeamCurrent Situation and ProblemsLeaderCurrently the schedule shows the type of cookie and number of batches for the week. When the pre scaler workers starts to collect and measure out ingredients they do not always check if all the need ingredients needed for the day are there. This can causeCo-leaderFacilitatorSenseiManagersFloor personnelStaff personnelProduction IncreaseOutside EyesIncrease communicationIf missing ingredients, increase of 20 to 60 minutes of pre scaling total available time per product typeResources on call:Ingredient checklist7 Batches sub shopINGREDIENTSFULL BAGSPARTIALBrown Sugar84853339Vream Rite Shortening27149842Bessie Flour08485421Am. Beauty Cake Flour5204601527Chocolate Chips-1000 ct08875598

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Kaizen PlanEvent Plan (Current and future state, and gap)Event Description (work center, performance measure to be focused on)Add labels to pre-scaled ingredientsThis is not a kaizen this is a project we will put together after asking if people on the floor agree, then will show the workers how it works and test the idea.Event Dates and TimesPreliminary Objectives20 minutes to explain labelsAdd labels to the scaled ingredient buckets to standardize the pre scaling process to eliminate errors and wait time. Creates a visual aid in order to see where the pre scaling process is at and what needs to be done next.test for a week, then decideCurrent Process (flow chart)Currently there are no labels on pre scaled ingredients. This leaves the possibility for errors and lacks important communication. If a worker leaves for break the helper can not easily pick up where they left off as they are not sure what has been scaledTeamCurrent Situation and ProblemsLeaderCurrently a worker fills a container of pre scaled ingredients, yet there is no documentation of how many pounds or what ingredients have been added so far. This makes it hard to tell what is there and what still needs to be done. It also is hard for a seCo-leaderFacilitatorSenseiManagersFloor personnelStaff personnelProduction IncreaseOutside EyesReduce errorsIncrease communicationResources on call:

Kaizen Plan (2)Event Plan (Current and future state, and gap)Event Description (work center, performance measure to be focused on)Modify cookies recipes formatThis is not a kaizen, this is a project. We will put together after asking if people on the floor agree, then will show the workers how it works and test the idea.Event Dates and TimesPreliminary Objectives20 minutes to explain recipeModify the cookie recipes to eliminate the math required to find the number of pounds that must be pre scaled and the number of full bags needed.test for a week, then decideCurrent Process (flow chart)TeamCurrent Situation and ProblemsLeaderRIT TeamCurrently the recipes cards have the total pounds needed for each ingredient. The pre scaler worker must take out a calculator and divide out the fill number of bags needed and then take the remainder and pre scale into a separate bucket. This leaves a large possibility for error in the calculation and takes time. This number is constant and does not need to be calculated every time.Co-leaderFacilitatorBridget EggersSenseiManagersFloor personnelNoneStaff personnelNoneProduction IncreaseOutside EyesIncrease in pre scaling total available time of 5 minutesReduce errorsResources on call:BAKESHOP FORMULAITEM:Cookie Pucks no Nuts-#197668DATE:11/10/13%INGREDIENTSSINGLE(lbs)FUL BAGSPARTIAL(lbs)Triple(lbs)FUL BAGSPARTIAL(lbs)PROCEDURESSTAGE 121.76Brown Sugar8485379129237437Cream together for19.78Vream Rite Shortening27149850201506020 seconds0.61Salt2976372.202.26.606.60.61Baking Soda0722002.202.26.606.6STAGE 213.78Bessie Flour084854501015030Add to above on high for10.2Am. Beauty Cake Flour520460370371112112 minutesSTAGE 35.09Liquid Whole Eggs07235218.5018.555.5055.5Add to above on high for 3 minutes1.1Clear Vanilla Extract042752404120120.28FB Soybean Oil(buckets)326108101303STAGE 432.79Chocolate Chips-1000 ct088755116.67416.67350.01140Add to above on mixthoroughly on high for 1 min90 COOKIES PER CASE100TOTAL:360.571081.71

Kaizen Plan (3)Event Plan (Current and future state, and gap)Event Description (work center, performance measure to be focused on)Checklist of whether ingredients are there before starting a batchThis is not a kaizen this is a project we will put together after asking if people on the floor agree, then will show the workers how it works and test the idea.Event Dates and TimesPreliminary Objectives20 minutes to explain checklistMake a checklist of all the ingredients that will be needed for the day so that the worker can check that they are all there before starting on the job. This will reduce wasted time in pre scaling out ingredients used if all ingredients for the batch aretest for a week, then decideCurrent Process (flow chart)ScheduleType, # batchesrealize that there are not enough chocolate chipsCollect some ingredientschange to different type of cookiespre scale out ingredientsmust re start pre scalingMixTeamCurrent Situation and ProblemsLeaderCurrently the schedule shows the type of cookie and number of batches for the week. When the pre scaler workers starts to collect and measure out ingredients they do not always check if all the need ingredients needed for the day are there. This can causeCo-leaderFacilitatorSenseiManagersFloor personnelStaff personnelProduction IncreaseOutside EyesIncrease communicationIf missing ingredients, increase of 20 to 60 minutes of pre scaling total available time per product typeResources on call:Ingredient checklist7 Batches sub shopINGREDIENTSFULL BAGSPARTIALBrown Sugar84853339Vream Rite Shortening27149842Bessie Flour08485421Am. Beauty Cake Flour5204601527Chocolate Chips-1000 ct08875598

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Kaizen PlanKaizen Event Plan (Current and future state, and gap)Event Description (work center, performance measure to be focused on)Have all boxes opened before being placed beside the mixerEvent Dates and TimesPreliminary Objectives1/2 hour to explain the plan to people on the floorOpen all boxes in the pre scaling stage to reduce the wasted time once on the mixer. Reduce the cycle time by 17% by eliminating the steps involved in opening boxes.1/2 hour to discuss with floor the possible solutions1/2 hour plan how to make this possible2 hours to test experiment3-4 hours total, less than half dayCurrent Process (flow chart)Cycle time 35 minutesOpening boxes 5 minTeamCurrent Situation and ProblemsLeaderCurrently ingredient boxes are opened while on the mixer stand, this is wasted time that the mixer should be running. The time that the mixer is sitting idle while non value added work is being done is a waste and reduces the daily cookie production.Co-leaderFacilitatorSenseiManagersFloor personnelStaff personnelProduction IncreaseOutside EyesIncrease in 5 minutes of available mixing time (7 cases), each batch10 minutes added to pre scaling total timeResources on call:

Kaizen Plan0.37430555560.19861111110.51527777780.20833333330.01875

Sub Shop w nuts

Kaizen Plan (2)Kaizen Event Plan (Current and future state, and gap)Event Description (work center, performance measure to be focused on)Scale liquids (eggs, vanilla) ahead then store in pie roomEvent Dates and Times1/2 hour to explain the plan to people on the floor1/2 hour to discuss with floor the possible solutions1/2 hour plan how to make this possible1 hours to test experimentPreliminary Objectives2-3 hours total, less than half dayScale out all batches eggs (10 min)Move to mixer stand (2 min)Add ingredients (12 min)Current Process (flow chart)Mix (9 min)Empty Mixer (5 min)Scale out eggs (5 min)Move to mixer stand (2 min)Add ingredients (12 min)The operator scales all batches of eggs out before the commercial operator has finished with the mixer. Place scaled out buckets in the cooler room next door. When starting a new batch the operator grab the bucket from the cooler and start mixing.Mix (9 min)Empty Mixer (5 min)TeamCurrent Situation and ProblemsLeaderEggs and vanilla are pre scaled out before each batch, this can take from 5 to 7 minutes. The mixer operator must leave the mixer stand and go to the egg tank, measure out the ingredients. Then come back to the stand and start a new batch. This is an addeCo-leaderFacilitatorSenseiManagersFloor personnelStaff personnelProduction IncreaseOutside EyesIncrease in 5 minutes of available mixing time (7 cases), each batch10 minutes added to pre scaling total timeResources on call:

Kaizen Plan (3)Kaizen Event Plan (Current and future state, and gap)Event Description (work center, performance measure to be focused on)Ingredients checklist of whether ingredients are there before starting a batch. This is not a kaizen, this is a project. We will put together after asking if people on the floor agree, then will show the workers how it works and test the idea.Event Dates and TimesCurrent Situation and Problems30 mins to explain ingredients checklist 1 wk for testing and refiningCurrently the schedule shows the type of cookie and number of batches for the week. When the pre scaler workers starts to collect and measure out ingredients they do not always check if all the need ingredients needed for the day are there. This can cause wasted time if there ends up being enough of the necessary ingredients. As a new type of cookie must be selected and all of the already selected ingredients are not needed.Current Process (flow chart)Production IncreaseIncrease communicationIf missing ingredients, increase of 20 to 60 minutes of pre scaling total available time per product typePreliminary ObjectivesMake a checklist of all the ingredients that will be needed for the day so that the worker can check that they are all there before starting on the job. This will reduce wasted time in pre scaling out ingredients used if all ingredients for the batch are not there. This will also prepare management for changes early in the day. So that the schedule can be updated.TeamLeaderRIT TeamCo-leaderFacilitatorBridget EggersSenseiManagersFloor personnelNoneStaff personnelNoneOutside EyesResources on call:

Sheet3

MBD0079EEC5.vsd

Receive schedule

Collect some ingredients

Pre-scale ingredients

Are there enough ingredients for # of batches?

Determine cookie type & # of batches

Finish pre-scaling

Decide on new cookie type & # of batches

Yes

No

Kaizen PlanKaizen Event Plan (Current and future state, and gap)Event Description (work center, performance measure to be focused on)Have all boxes opened before being placed beside the mixerEvent Dates and TimesPreliminary Objectives1/2 hour to explain the objective to line workersOpen all boxes in the pre scaling stage to reduce the wasted time once on the mixer. Reduce the cycle time by 17% by eliminating the steps involved in opening boxes.1/2 hour to discuss with floor the possible solutions1/2 hour plan how to make this possible2 hours to test experiment3-4 hours total, less than half dayCurrent Process (flow chart)Cycle time 35 minutesOpening boxes 5 minTeamCurrent Situation and ProblemsLeaderRIT TeamCurrently ingredient boxes are opened while on the mixer stand, this is wasted time that the mixer should be running. The time that the mixer is sitting idle while non value added work is being done is a waste and reduces the daily cookie production.Co-leaderFacilitatorBridget EggersSenseiManagersFloor personnelStaff personnelTeam leaderProduction IncreaseOutside EyesIncrease in 5 minutes of available mixing time (7 cases), each batch10 minutes added to pre scaling total timeResources on call:

Kaizen Plan0.37430555560.19861111110.51527777780.20833333330.01875

Sub Shop w nuts

Kaizen Plan (2)Kaizen Event Plan (Current and future state, and gap)Event Description (work center, performance measure to be focused on)Scale liquids (eggs, vanilla) ahead then store in pie roomEvent Dates and Times1/2 hour to explain the plan to people on the floor1/2 hour to discuss with floor the possible solutions1/2 hour plan how to make this possible1 hours to test experimentPreliminary Objectives2-3 hours total, less than half dayScale out all batches eggs (10 min)Move to mixer stand (2 min)Add ingredients (12 min)Current Process (flow chart)Mix (9 min)Empty Mixer (5 min)Scale out eggs (5 min)Move to mixer stand (2 min)Add ingredients (12 min)The operator scales all batches of eggs out before the commercial operator has finished with the mixer. Place scaled out buckets in the cooler room next door. When starting a new batch the operator grab the bucket from the cooler and start mixing.Mix (9 min)Empty Mixer (5 min)TeamCurrent Situation and ProblemsLeaderEggs and vanilla are pre scaled out before each batch, this can take from 5 to 7 minutes. The mixer operator must leave the mixer stand and go to the egg tank, measure out the ingredients. Then come back to the stand and start a new batch. This is an addeCo-leaderFacilitatorSenseiManagersFloor personnelStaff personnelProduction IncreaseOutside EyesIncrease in 5 minutes of available mixing time (7 cases), each batch10 minutes added to pre scaling total timeResources on call:

Kaizen Plan (3)Kaizen Event Plan (Current and future state, and gap)Event Description (work center, performance measure to be focused on)Enforced material handling rolesEvent Dates and TimesPreliminary Objectives1/2 hour to explain plan, then test for a week and decide if it's working, discuss and decide what works bestEnforce the material handler roles for the collection and returning of ingredients. Standardize the method of communication is what must be collected, when and where it should be placed. As well as a standard way to communicate when ingredients will needCurrent Process (flow chart)Operator must return all ingredients from last productOperator retrieves all needed ingredients for current productStarts mixingMust stop is ingredients run outOperator goes and gets more ingredientsStarts MixingFinishes mixingReturns all ingredientsTeamCurrent Situation and ProblemsLeaderMixer operator must collect and return all ingredients. This causes long delays in the mixing process. The forklifts are shared and can have long wait periods before one becomes available. When an ingredient runs out the mixing operator must stop workingCo-leaderFacilitatorSenseiManagersFloor personnelStaff personnelProduction IncreaseOutside EyesIncrease in 20 minutes of available mixing time (36 cases)30 minutes removed from pre scaling total timeResources on call:

Sheet3

Kaizen PlanKaizen Event Plan (Current and future state, and gap)Event Description (work center, performance measure to be focused on)Have all boxes opened before being placed beside the mixerEvent Dates and TimesPreliminary Objectives1/2 hour to explain the plan to people on the floorOpen all boxes in the pre scaling stage to reduce the wasted time once on the mixer. Reduce the cycle time by 17% by eliminating the steps involved in opening boxes.1/2 hour to discuss with floor the possible solutions1/2 hour plan how to make this possible2 hours to test experiment3-4 hours total, less than half dayCurrent Process (flow chart)Cycle time 35 minutesOpening boxes 5 minTeamCurrent Situation and ProblemsLeaderCurrently ingredient boxes are opened while on the mixer stand, this is wasted time that the mixer should be running. The time that the mixer is sitting idle while non value added work is being done is a waste and reduces the daily cookie production.Co-leaderFacilitatorSenseiManagersFloor personnelStaff personnelProduction IncreaseOutside EyesIncrease in 5 minutes of available mixing time (7 cases), each batch10 minutes added to pre scaling total timeResources on call:

Kaizen Plan0.37430555560.19861111110.51527777780.20833333330.01875

Sub Shop w nuts

Kaizen Plan (2)Kaizen Event Plan (Current and future state, and gap)Event Description (work center, performance measure to be focused on)Scale liquids (eggs, vanilla) ahead then store in pie roomEvent Dates and Times1/2 hour to explain the objective to line workers1/2 hour to discuss with floor the possible solutions1/2 hour plan how to make this possible1 hours to test experimentPreliminary Objectives2-3 hours total, less than half dayScale out all batches eggs (10 min)Move to mixer stand (2 min)Add ingredients (12 min)Current Process (flow chart)Mix (9 min)Empty Mixer (5 min)Scale out eggs (5 min)Move to mixer stand (2 min)Add ingredients (12 min)The operator scales all batches of eggs out before the commercial operator has finished with the mixer. Place scaled out buckets in the cooler room next door. When starting a new batch the operator grab the bucket from the cooler and start mixing.Mix (9 min)Empty Mixer (5 min)TeamCurrent Situation and ProblemsLeaderRIT TeamEggs and vanilla are pre scaled out before each batch, this can take from 5 to 7 minutes. The mixer operator must leave the mixer stand and go to the egg tank, measure out the ingredients. Then come back to the stand and start a new batch. This is an added 5 minutes to every batch where the mixer is sitting idle.Co-leaderFacilitatorBridget EggersSenseiManagersFloor personnelStaff personnelTeam leaderProduction IncreaseOutside EyesIncrease in 5 minutes of available mixing time for each batch (7 cases)Resources on call:10 minutes added to pre scaling total time

Kaizen Plan (3)Kaizen Event Plan (Current and future state, and gap)Event Description (work center, performance measure to be focused on)Enforced material handling rolesEvent Dates and TimesPreliminary Objectives1/2 hour to explain plan, then test for a week and decide if it's working, discuss and decide what works bestEnforce the material handler roles for the collection and returning of ingredients. Standardize the method of communication is what must be collected, when and where it should be placed. As well as a standard way to communicate when ingredients will needCurrent Process (flow chart)Operator must return all ingredients from last productOperator retrieves all needed ingredients for current productStarts mixingMust stop is ingredients run outOperator goes and gets more ingredientsStarts MixingFinishes mixingReturns all ingredientsTeamCurrent Situation and ProblemsLeaderMixer operator must collect and return all ingredients. This causes long delays in the mixing process. The forklifts are shared and can have long wait periods before one becomes available. When an ingredient runs out the mixing operator must stop workingCo-leaderFacilitatorSenseiManagersFloor personnelStaff personnelProduction IncreaseOutside EyesIncrease in 20 minutes of available mixing time (36 cases)30 minutes removed from pre scaling total timeResources on call:

Sheet3

Kaizen PlanKaizen Event Plan (Current and future state, and gap)Event Description (work center, performance measure to be focused on)Have all boxes opened before being placed beside the mixerEvent Dates and TimesPreliminary Objectives1/2 hour to explain the plan to people on the floorOpen all boxes in the pre scaling stage to reduce the wasted time once on the mixer. Reduce the cycle time by 17% by eliminating the steps involved in opening boxes.1/2 hour to discuss with floor the possible solutions1/2 hour plan how to make this possible2 hours to test experiment3-4 hours total, less than half dayCurrent Process (flow chart)Cycle time 35 minutesOpening boxes 5 minTeamCurrent Situation and ProblemsLeaderCurrently ingredient boxes are opened while on the mixer stand, this is wasted time that the mixer should be running. The time that the mixer is sitting idle while non value added work is being done is a waste and reduces the daily cookie production.Co-leaderFacilitatorSenseiManagersFloor personnelStaff personnelProduction IncreaseOutside EyesIncrease in 5 minutes of available mixing time (7 cases), each batch10 minutes added to pre scaling total timeResources on call:

Kaizen Plan0.37430555560.19861111110.51527777780.20833333330.01875

Sub Shop w nuts

Kaizen Plan (2)Kaizen Event Plan (Current and future state, and gap)Event Description (work center, performance measure to be focused on)Scale liquids (eggs, vanilla) ahead then store in pie roomEvent Dates and Times1/2 hour to explain the plan to people on the floor1/2 hour to discuss with floor the possible solutions1/2 hour plan how to make this possible1 hours to test experimentPreliminary Objectives2-3 hours total, less than half dayScale out all batches eggs (10 min)Move to mixer stand (2 min)Add ingredients (12 min)Current Process (flow chart)Mix (9 min)Empty Mixer (5 min)Scale out eggs (5 min)Move to mixer stand (2 min)Add ingredients (12 min)The operator scales all batches of eggs out before the commercial operator has finished with the mixer. Place scaled out buckets in the cooler room next door. When starting a new batch the operator grab the bucket from the cooler and start mixing.Mix (9 min)Empty Mixer (5 min)TeamCurrent Situation and ProblemsLeaderEggs and vanilla are pre scaled out before each batch, this can take from 5 to 7 minutes. The mixer operator must leave the mixer stand and go to the egg tank, measure out the ingredients. Then come back to the stand and start a new batch. This is an addeCo-leaderFacilitatorSenseiManagersFloor personnelStaff personnelProduction IncreaseOutside EyesIncrease in 5 minutes of available mixing time (7 cases), each batch10 minutes added to pre scaling total timeResources on call:

Kaizen Plan (3)Kaizen Event Plan (Current and future state, and gap)Event Description (work center, performance measure to be focused on)Standardize material handling rolesEvent Dates and TimesPreliminary Objectives1/2 hour to explain objective, then test for a week and decide if it's working, discuss and decide what works bestStandardize the material handler roles for the collection and returning of ingredients. Standardize the method of communication is what must be collected, when and where it should be placed. As well as a standard way to communicate when ingredients will need to be returned. This should also include a way for the material handler to know when to come replenish an ingredient.Current Process (flow chart)Operator must return all ingredients from last productOperator retrieves all needed ingredients for current productStarts mixingMust stop is ingredients run outOperator goes and gets more ingredientsStarts MixingFinishes mixingReturns all ingredientsTeamCurrent Situation and ProblemsLeaderRIT TeamMixer operator must collect and return all ingredients. This causes long delays in the mixing process. The forklifts are shared and can have long wait periods before one becomes available. When an ingredient runs out the mixing operator must stop working and find a forklift and collect their ingredients.During this time the mixer is sitting idle which reduces production output.Co-leaderFacilitatorBridget EggersSenseiManagersFloor personnelStaff personnelTeam leaderProduction IncreaseOutside EyesIncrease in 20 minutes of available mixing time (36 cases)30 minutes removed from pre scaling total timeResources on call:

Sheet3

Kaizen PlanKaizen Event Plan (Current and future state, and gap)Event Description (work center, performance measure to be focused on)Have all boxes opened before being placed beside the mixerEvent Dates and TimesPreliminary Objectives1/2 hour to explain the plan to people on the floorOpen all boxes in the pre scaling stage to reduce the wasted time once on the mixer. Reduce the cycle time by 17% by eliminating the steps involved in opening boxes.1/2 hour to discuss with floor the possible solutions1/2 hour plan how to make this possible2 hours to test experiment3-4 hours total, less than half dayCurrent Process (flow chart)Cycle time 35 minutesOpening boxes 5 minTeamCurrent Situation and ProblemsLeaderCurrently ingredient boxes are opened while on the mixer stand, this is wasted time that the mixer should be running. The time that the mixer is sitting idle while non value added work is being done is a waste and reduces the daily cookie production.Co-leaderFacilitatorSenseiManagersFloor personnelStaff personnelProduction IncreaseOutside EyesIncrease in 5 minutes of available mixing time (7 cases), each batch10 minutes added to pre scaling total timeResources on call:

Kaizen Plan0.37430555560.19861111110.51527777780.20833333330.01875

Sub Shop w nuts

Kaizen Plan (2)Kaizen Event Plan (Current and future state, and gap)Event Description (work center, performance measure to be focused on)Scale liquids (eggs, vanilla) ahead then store in pie roomEvent Dates and Times1/2 hour to explain the plan to people on the floor1/2 hour to discuss with floor the possible solutions1/2 hour plan how to make this possible1 hours to test experimentPreliminary Objectives2-3 hours total, less than half dayScale out all batches eggs (10 min)Move to mixer stand (2 min)Add ingredients (12 min)Current Process (flow chart)Mix (9 min)Empty Mixer (5 min)Scale out eggs (5 min)Move to mixer stand (2 min)Add ingredients (12 min)The operator scales all batches of eggs out before the commercial operator has finished with the mixer. Place scaled out buckets in the cooler room next door. When starting a new batch the operator grab the bucket from the cooler and start mixing.Mix (9 min)Empty Mixer (5 min)TeamCurrent Situation and ProblemsLeaderEggs and vanilla are pre scaled out before each batch, this can take from 5 to 7 minutes. The mixer operator must leave the mixer stand and go to the egg tank, measure out the ingredients. Then come back to the stand and start a new batch. This is an addeCo-leaderFacilitatorSenseiManagersFloor personnelStaff personnelProduction IncreaseOutside EyesIncrease in 5 minutes of available mixing time (7 cases), each batch10 minutes added to pre scaling total timeResources on call:

Kaizen Plan (3)Kaizen Event Plan (Current and future state, and gap)Event Description (work center, performance measure to be focused on)Reduce waiting time associated with cleaning process and non-value added work completed during mixer idle time.Event Dates and TimesCurrent Situation and Problems1/2 hour meeting with sanitation1/2 hour to explain plan1 week to implement kaizen1 week for data analysis and reviewMixing operator has to wait for sanitation to arrive and complete their process before the operator can perform their work. Operator folds and disposes boxes while mixer is idle, which takes away mixing time that can be utilized.Current Process (flow chart)Production IncreaseIncrease in 10-25 minutes per day in recovered sanitation time (18-45 cases per day).Breaking down boxes would result in an increase of 2-4 minutes per batch (4-7 cases per batch)Preliminary ObjectivesChange sanitation process so that all sanitation processes that are not "deep clean" can be done by the mixer operator.

Revise fold and dispose box process to perform task when mixing is not being used.TeamLeaderRIT TeamCo-leaderFacilitatorRichard LathamSenseiManagersFloor personnelStaff personnelOutside EyesResources on call:

Sheet3

MBD01141763.vsd

MixingWork Processes

Normal

Abnormal

Value-Added

Non-Value Added

Cleaning

Fold and Dispose Boxes

Necessary

Unncecessary

Mixing

MH

Kaizen PlanKaizen Event Plan (Current and future state, and gap)Event Description (work center, performance measure to be focused on)Modify methodology for scheduling dividing time for frozen cookies around ensuring that only one type of machine is used per day and that the machine is set up on time to meet the schedule.Event Dates and Times4 hours - interviews with different planners and team leader.2 hours - map decision flow procedures1 hour - present new procedures2 weeks - monitor procedure change by changes in dataCurrent Situation and ProblemsCurrent feedback loop between team leader and Frozen Cookie Line Scheduler doesn't take into affect past tendencies for the machines to not get set up on time and a large changeover time exists between different frozen cooke line machines. No real decision matrix in how floor can impact scheduling.Current Process (flow chart)Preliminary ObjectivesCreate decision matrix for interpreting decisions made by production scheduler based on received input (from floor, commercial scheduler, master scheduler, and forecasting scheduler)

Create decision matrix on feedback mechanism that line leader provides to scheduler.

Limit or eliminate the need for two machines per day.TeamLeader:RIT TeamCo-leader:Facilitator:Richard LathamSenseiManagersFloor personnelBill HoldenStaff personnelKathleen Endres, Andy Mullings, Jeff HillOutside EyesResources on call:

Target sheetKAIZEN EVENT TARGET SHEETEvent Description (work center, performance measure to be focused on)Event DatesCreate individual schedules for scaling, mixing, and dividing that reflect changes that happen during the week/day. This will give a more accurate idea of when these tasks need to be done, and how many batches can be made on any specific day.February 3rd - 7th, 2014CurrentTargetDay 1Day 2Day 3Day 4Final% ImprovementProcess cycle timeVolume per daySpace (sq. in.)Inventory (days)Walking distanceParts transport distanceFull time equivalent peopleChangeover timeQuality improvementsVisual controlsSafety improvementsPoke yoke improvementsComments regarding changes madeNote: use only the applicable metrics, keep the focus of the plan on what is important

Sheet3

MBD039F6D80.vsd

Team Leader

There is a problem w/ next weeks schedule

T

Master Scheduler

Forecaster(Demand Planning)

Commercial Cookie Line Scheduler

Frozen Cookie Line Scheduler

Kaizen PlanKaizen Event Plan (Current and future state, and gap)Event Description (work center, performance measure to be focused on)Have all boxes opened before being placed beside the mixerEvent Dates and TimesPreliminary Objectives1/2 hour to explain the plan to people on the floorOpen all boxes in the pre scaling stage to reduce the wasted time once on the mixer. Reduce the cycle time by 17% by eliminating the steps involved in opening boxes.1/2 hour to discuss with floor the possible solutions1/2 hour plan how to make this possible2 hours to test experiment3-4 hours total, less than half dayCurrent Process (flow chart)Cycle time 35 minutesOpening boxes 5 minTeamCurrent Situation and ProblemsLeaderCurrently ingredient boxes are opened while on the mixer stand, this is wasted time that the mixer should be running. The time that the mixer is sitting idle while non value added work is being done is a waste and reduces the daily cookie production.Co-leaderFacilitatorSenseiManagersFloor personnelStaff personnelProduction IncreaseOutside EyesIncrease in 5 minutes of available mixing time (7 cases), each batch10 minutes added to pre scaling total timeResources on call:

Kaizen Plan0.37430555560.19861111110.51527777780.20833333330.01875

Sub Shop w nuts

Kaizen Plan (2)Kaizen Event Plan (Current and future state, and gap)Event Description (work center, performance measure to be focused on)Scale liquids (eggs, vanilla) ahead then store in pie roomEvent Dates and Times1/2 hour to explain the plan to people on the floor1/2 hour to discuss with floor the possible solutions1/2 hour plan how to make this possible1 hours to test experimentPreliminary Objectives2-3 hours total, less than half dayScale out all batches eggs (10 min)Move to mixer stand (2 min)Add ingredients (12 min)Current Process (flow chart)Mix (9 min)Empty Mixer (5 min)Scale out eggs (5 min)Move to mixer stand (2 min)Add ingredients (12 min)The operator scales all batches of eggs out before the commercial operator has finished with the mixer. Place scaled out buckets in the cooler room next door. When starting a new batch the operator grab the bucket from the cooler and start mixing.Mix (9 min)Empty Mixer (5 min)TeamCurrent Situation and ProblemsLeaderEggs and vanilla are pre scaled out before each batch, this can take from 5 to 7 minutes. The mixer operator must leave the mixer stand and go to the egg tank, measure out the ingredients. Then come back to the stand and start a new batch. This is an addeCo-leaderFacilitatorSenseiManagersFloor personnelStaff personnelProduction IncreaseOutside EyesIncrease in 5 minutes of available mixing time (7 cases), each batch10 minutes added to pre scaling total timeResources on call:

Kaizen Plan (4)Kaizen Event Plan (Current and future state, and gap)Event Description (work center, performance measure to be focused on)Ingredients checklist of whether ingredients are there before starting a batch. This is not a kaizen, this is a project. We will put together after asking if people on the floor agree, then will show the workers how it works and test the idea.Event Dates and TimesCurrent Situation and Problems30 mins to explain ingredients checklist 1 wk for testing and decideCurrently the schedule shows the type of cookie and number of batches for the week. When the pre scaler workers starts to collect and measure out ingredients they do not always check if all the need ingredients needed for the day are there. This can causeCurrent Process (flow chart)Production IncreaseIncrease communicationIf missing ingredients, increase of 20 to 60 minutes of pre scaling total available time per product typePreliminary ObjectivesMake a checklist of all the ingredients that will be needed for the day so that the worker can check that they are all there before starting on the job. This will reduce wasted time in pre scaling out ingredients used if all ingredients for the batch areTeamLeaderRIT TeamCo-leaderFacilitatorBridget EggersSenseiManagersFloor personnelNoneStaff personnelNoneOutside EyesResources on call:

Kaizen Plan (3)Kaizen Event Plan (Current and future state, and gap)Event Description (work center, performance measure to be focused on)Reduce variability between plan vs. scheduled processing times by implementingEvent Dates and TimesCurrent Situation and Problems4 hrs interviews with production planning 1 hr to explain objective, and collect input from line workers 1 wk of schedule design2 wks of implementation and tracking1 wk of review and redesign 1wk of final implementationCurrent schedule does not reflect cleaning, changeover, and other neccesary activities' times. In addition, if any issue comes up, schedule are not updated accordingly and the issues are not communicated effectivly delaying other tasks on the line. Workers breaks affect the time each station is actually running.Current Process (flow chart)Production Increase- Workers take a 15 mins break every 2 hours- Avg mixer cleaning time = 12min - Avg divider changeover time = 33 mins - Actual vs. planned mixing process time (depends on cookie type)- Avg. divider running time = 2 hrs and 33 minPreliminary Objectives- Increase frozen cookies production time- Place individual schedules close to stations - Add changeover/cleaning time into schedules- Offset workers' breaks or have helpers to cover breaks- Determine avg process times for observed cookie types - Once improvements are recorded and accurately measured, propose a project to modify spiral #2 schedule (High level modifications)Actual vs. Scheduled Packaging TimesTeamLeaderRIT TeamCo-leaderFacilitatorValeria GonzalezSenseiManagersFloor personnelStaff personnelOutside EyesResources on call:

Sheet3

MBD007AB7B4.vsd

Receive schedule

Collect some ingredients

Pre-scale ingredients

Are there enough ingredients for # of batches?

Determine cookie type & # of batches

Finish pre-scaling

Decide on new cookie type & # of batches

Yes

No

Kaizen PlanKaizen Event Plan (Current and future state, and gap)Event Description (work center, performance measure to be focused on)Have all boxes opened before being placed beside the mixerEvent Dates and TimesPreliminary Objectives1/2 hour to explain the plan to people on the floorOpen all boxes in the pre scaling stage to reduce the wasted time once on the mixer. Reduce the cycle time by 17% by eliminating the steps involved in opening boxes.1/2 hour to discuss with floor the possible solutions1/2 hour plan how to make this possible2 hours to test experiment3-4 hours total, less than half dayCurrent Process (flow chart)Cycle time 35 minutesOpening boxes 5 minTeamCurrent Situation and ProblemsLeaderCurrently ingredient boxes are opened while on the mixer stand, this is wasted time that the mixer should be running. The time that the mixer is sitting idle while non value added work is being done is a waste and reduces the daily cookie production.Co-leaderFacilitatorSenseiManagersFloor personnelStaff personnelProduction IncreaseOutside EyesIncrease in 5 minutes of available mixing time (7 cases), each batch10 minutes added to pre scaling total timeResources on call:

Kaizen Plan0.37430555560.19861111110.51527777780.20833333330.01875

Sub Shop w nuts

Kaizen Plan (2)Kaizen Event Plan (Current and future state, and gap)Event Description (work center, performance measure to be focused on)Scale liquids (eggs, vanilla) ahead then store in pie roomEvent Dates and Times1/2 hour to explain the plan to people on the floor1/2 hour to discuss with floor the possible solutions1/2 hour plan how to make this possible1 hours to test experimentPreliminary Objectives2-3 hours total, less than half dayScale out all batches eggs (10 min)Move to mixer stand (2 min)Add ingredients (12 min)Current Process (flow chart)Mix (9 min)Empty Mixer (5 min)Scale out eggs (5 min)Move to mixer stand (2 min)Add ingredients (12 min)The operator scales all batches of eggs out before the commercial operator has finished with the mixer. Place scaled out buckets in the cooler room next door. When starting a new batch the operator grab the bucket from the cooler and start mixing.Mix (9 min)Empty Mixer (5 min)TeamCurrent Situation and ProblemsLeaderEggs and vanilla are pre scaled out before each batch, this can take from 5 to 7 minutes. The mixer operator must leave the mixer stand and go to the egg tank, measure out the ingredients. Then come back to the stand and start a new batch. This is an addeCo-leaderFacilitatorSenseiManagersFloor personnelStaff personnelProduction IncreaseOutside EyesIncrease in 5 minutes of available mixing time (7 cases), each batch10 minutes added to pre scaling total timeResources on call:

Kaizen Plan (3)Labor Management Improvement ProjectEvent Description (work center, performance measure to be focused on)Evaluate employee roles and identify potential downtime scenarios. Based on employee tasks and scheduling implement cross training to increase employee utilization and efficiency.Event Dates and TimesProduction Increase30-60 min meeting to discuss opportunities1-4 hour increments to test potential scenarios1-2 hours to evaluate impact on systemIncrease in overall employee utilization of 15-30 minutes (27-54 cases) daily.Current ProcessPreliminary ObjectivesCross training exists but has limited roles. Employees are typically dedicated to a specific resource or task within a production line. For example, a mixer operator for the commercial cookie line or a divider operator for the frozen cookie line. With small exceptions, employees remain with their given task for a specific time or production interval, regardless of downtime.Increase employee utilization by eliminating downtime. Increase system production capacity through increased utilization.TeamLeaderRIT TeamCo-leaderFacilitatorTyler BrentCurrent Situation and ProblemsSenseiProduction line is not balanced and presents situations were employees are idle. These employees could be utilized for additional task during their downtime.ManagersFloor personnelStaff personnelOutside EyesResources on call:

Sheet3

Kaizen PlanKaizen Event Plan (Current and future state, and gap)Event Description (work center, performance measure to be focused on)Document most effective and efficient procedures based on time studies and observations. Formulate standard work instructions based on information necessary to complete a given task.Event Dates and TimesPreliminary Objectives1/2 hour to discuss procedures and current standard work (if any) for each stationIdentify best practices and procedures for scaling, mixing and dividing (most effective and efficient).

Standardize best practices and procedures for scaling, mixing and dividing.

Create and test standard work instructions with different employees and procedures.3-4 hours to experiment with different template structure and user friendliness for each station4 hours to create and evaluate standard work instructions for all product types per stationApproximately 8 hours per station totalCurrent Situation and ProblemsDifferent employees complete tasks in different sequences. Increasing the probability of errors as well as variability in cycle time.Lack of instructional documentation prolongs training of employeesProduction Requirements (takt time)Team5% decrease in scaling cycle times for cycles that are conducted not following best practices.LeaderRIT Team10-15% decrease in mixer cycle time for cycles that are conducted not following best practices.Co-leaderFacilitatorTyler Brent5% decrease in dividing cycle time for cycles that are conducted not following best practices.SenseiManagersFloor personnelStaff personnelOutside EyesResources on call:

Target sheetKAIZEN EVENT TARGET SHEETEvent Description (workcenter, performance measure to be focused on)Event DatesCurrentTargetDay 1Day 2Day 3Day 4Final% ImprovementProcess cycle timeVolume per daySpace (sq. ft.)InventoryWalking distanceParts transport distanceFull time equivalent peopleChangeover timeQuality improvementsVisual controlsSafety improvementsPoke yoke improvementsComments regarding changes made

Sheet3