Meeting Purpose:

Review the DMAIC process and project timeline.

Finalize the Measure phase of the project including current process state, current layout, current ergonomics, equipment needs, and project specifications.

Discuss the ergonomic analysis and the resulting project specifications.

Review the current status of the Analysis phase, and discuss the plans for the completion of this phase. Present and review the proposed future process steps, the future layout and inventory management strategy, and the appropriate sifting and screening equipment.

Attendees:

Project Team: Erik Webster, Kate Gleason, Cecilia Enestrom, Grant Garbach, Andrew Tsai

Faculty Guides: John Kaemmerlen, Phil Bryan

Wegmans Representatives: Mike Least, Scott Young

Sweco Representative: Jonathan Ansley

Recorded by: Project Team Members

Meeting Date: Friday, February 13, 2009

Discussion:

Customer Needs

-Material loss per cycle missing data is less important than we thought it would be

-Probably not worth investigating more

-Some differences between printed version and power point

-Constraints should come out of customer needs specifications

-Marginal/Ideal values being same is not constructive

Ergonomics

-Why NIOSH? Phil Bryan inquired about its credibility

  • Erik: It was the most applicable method within our means (no 3DSSPP)

-For lifting index for ingredient bags, you are unloading pallets, not lifting pallets.

  • Design of graph is kind of unrepresentative of that order

Design Layout & Process Improvement

-Keep liquids in the back of your minds

  • Not sure how much space is needed for them

-Potential kanban system instead of specific schedule

  • Ahead and behind numbers?
  • Signaling number (eg if yeast is at 4 bags, restock it)
  • Harder to level

-Should we really be using peak ingredient usage to make the restocking schedule?

  • Probably not – see if we can use average usage

-Looks like there will be room to store the liquids

-Can we really eliminate dead time between preparation and the arrival of batch cards

-Think about where to put the carts for staging

-Look at layout of the bins

  • Something to consider for MSDII

Sifting & Screening Equipment

-If Scott needs more hours, we need to look at lowering the decibel level or protecting the workers

-Phil inquired about the classification of what is a “foreign material” that the sifting and screening equipment is trying to eliminate

-Phil believes there is a gap in the specified expectations

  • You are reducing “foreign material”, but how much? And what kinds?
  • You should specify having to screen out foreign material of a certain size and larger

-May be worth noting that mesh size was based on a certain ingredient and that other ingredients could use a different size

-50 lb bag through sifter to some kind of container – must think about this process

-Will a hood be necessary?

-Scott needs to know if the workers feel comfortable working on the high platforms

-How many people would be needed to get peak throughput?

  • Throughput is dependent on labor availability
  • Something to keep in mind for MSD II

-How many bags per shift does Scott want to be able to sift?

  • Depends on labor availability
  • Scott says that sifting/screening can be done when scaling is not being done

Action Items
Item # / Description / Responsible / Due Date / Close Date / Comments
A001 / Make corrections to project specifications / Erik Webster / 2/20/09 / 2/20/09 / Correct errors
A002 / Make corrections to the ergonomic graphs / Erik Webster / 2/20/09 / 2/20/09 / Backwards
A003 / Stocking schedule based on average ingredient usage / Kate Gleason / 3/13/09 / Current uses peak usage
A004 / Investigate kanban system for restocking / Kate Gleason / 3/13/09 / Schedule is infeasible
A005 / Include storage for liquid ingredients in layout / Cecilia Enestrom / 3/13/09 / Not included in layout
A006 / Determine optimal layout for scaling area / Cecilia Enestrom / 3/13/09
A007 / Finalize short-term storage layout / Cecilia Enestrom / 3/13/09 / Factor in restock and use
A008 / Specification for contaminants that can be sifted / Grant and Andrew / 3/13/09 / 3/13/09
A009 / Include equipment in layout and process / Project Team / 4/3/09 / Process, staffing, location
Issues
Item # / Description / Responsible / Open Date / Close Date / Comments
I001 / Errors in project specifications / Erik Webster / 2/13/09 / 2/20/09
I002 / Errors in ergonomics graphs / Erik Webster / 2/13/09 / 2/20/09 / Backwards
I003 / Restock cannot be based on schedule / Kate Gleason / 2/13/09 / Potential for kanban system
I004 / Liquid ingredients not included in layout / Cecilia Enestrom / 2/13/09
I005 / No specification for what constitutes foreign material / Grant Andrew / 2/13/09 / 3/13/09
I006 / Equipment not included in process / Project Team / 2/13/09
Decisions
Item # / Description / Contributing Individuals / Decision Date / Comments
D001 / Improvements must accommodate ergo specs / Mike and Scott / 2/13/09
D002 / Long-term and short-term storage locations / Mike and Scott / 2/13/09
D003 / Inventory management strategy in pallets / Mike and Scott / 2/13/09
D004 / Short-term storage restocking prior to scaling / Mike and Scott / 2/13/09
D005 / Sweco is optimal equipment selection / Mike and Scott / 2/13/09
D006 / Mike and Scott

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