SUBSYSTEMS DESIGN REVIEW Matthew Jackson, Derek Kreider, Emily Smith, Tashalynn Taylor

October 29, 2013

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Subsystems Design Summary Three Week Plan

Subsystems Design

Mixer Rheon Head Rheon Conveyor Oven Load

Introduction

Problem Statement Observation Times

Presentation Agenda

Problem Statement

Current State

Variable process times for sanitation at different stations on the ParBake line due to a wide variety of

products, environmental factors, and different operators

Current documentation allows processes to be repeatable between workers, but could still be

improved

Goal: Clean effectively (food safety) but efficiently (production time)

Desired State

Gain productivity hours on the ParBake line

Document of standard work and characterization of sanitation processes

Design a future state of ParBake line regarding process times, improvement opportunities, and a plan

for ensuring how standard work will be followed

Quantify the cost and time savings of proposed improvements

Test improvements through small kaizen projects

Constraints

Meet food safety requirements (post/pre operational checklists)

No improvements can result in a negative ergonomic impact on workers

Any tools used for improvement and sustainment of proposed changes must be easily accessible to

Wegmans

Observations

Mixer Rheon Head Rheon Conveyor Oven Load

Total Observations 8 4 3 3

Time Observations 6 3 3 2

Mixer

Total Time Range:

155 - 284 minutes

Rheon Head

Total Time Range:

67 - 121 minutes

Rheon Conveyor

Total Time Range:

70 - 105 minutes

Oven Load

Oven Load

Fairly simple process but due to equipment

constraints it is very ergonomically demanding

Process: Clean under oven load area

Range:

5 mins to 25 mins

SSD Summary

Requirements “flow down” to subsystems & are all

requirements addressed?

We are currently addressing all process time and

quality requirements, as well identifying sources of

variability

SSD Summary Cont.

Proof of concept and identify sources of variability

Most of the Variability is caused by:

• Product being run

• Technique used by worker

• Tools available to worker

• Operator performing task

• Number of workers performing

task

SSD Summary Cont.

How are you going to test that requirements are met?

Kaizens- small changes to the process to evaluate improvement

Worker/customer feedback- used to evaluate proposed improvements and documentation

Time study data analysis- used to quantify time and cost savings of improvements

Has your design been adequately reviewed?

Gone through problem definition and systems design review with peers, guide, and customers

Met with sanitation employees to discuss project and get buy in

Weekly meetings with guide to discuss progress and analytical methods used to evaluate the process

Three Week Project Plan

Week 10 – Continue to collect time study data,

and begin to develop visual tools for comparison of

actual practices to theoretical practices

Week 11 – Continue to collect time study, and

begin to shift focus to analysis of data

Week 12 – Continue to collect time study, and

continue to analyze the data

Questions & Feedback