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CHANGING THE
Through LEAN
DMAIC
DEFINE the Customer, their Critical to Quality (CTQ) issues, and the Core Business Process involved
Map Process Flow
ANALYZE the data collected and process map to determine root causes of defects and opportunities for improvement
Identify gaps between current performance and goal performance Prioritize opportunities to improve Identify sources of variation
IMPROVE the target process by designing creative solutions to fix and prevent problems
Create innovate solutions using technology and discipline Develop and deploy implementation plan
Process Mapping
1 dy a
1
Po u t toD c inWr h u e r dc ok ae o s Po u t S r d r d c toe inWr h u e ae o s P dc ro u t T n p r e to ra s ot d Le in Op r n f r p otu i o ty K n a to abn S n ln e ig a e d mrePll ts o ae T k B xf m ae t N F a e o ro P ll t o W
Si mn toD c h et p ok
1 hu or
P d c Wits ro ut a o P l t U ti n a le n l R a yfo Ue ed r s Be kOe B xo BxB a e r a p n o n o re k r
DCs g e a in A0
Po u t r dc U c s dfo N t nae r e Wig F e e h ill r Oe B x pn o Po ininN t r te e Wig F r eh i lle E dP in fo n ot r Mteia F w a r l lo . Cm o i i o md n ty Ta , E d ry n C s mr u to e Be kD w B x ra on o 1 sc 5 e
5 sc e 1 sc 0 e 1 Bx o 4 Bx s 5 oe
T r w u Bx ho Ot o
5 sc e 1 sc 0 e 1 Bx o 4 Bx s 5 oe 1 sc 5 e 2 sc 0 e
1 sc 0 e 1 0 sc e 1 Bx o 4 Bx s 5 oe 2 sc 5 e
1 sc 0 e 1 sc 5 e 1 Bx o 4 Bx s 5 oe
1 sc 0 e 1 sc 5 e 1 Bx o 4 Bx s 5 oe 2 sc 5 e 7 sc e
2 sc e 5 sc e
1 sc 0 e 5 sc e 1 sc 0 e 1 1 c sc 0 s e 0 e 1 sc 0 e 1 sc 5 e 1 sc 0 e 1 sc 5 e 2 sc e 5 sc e = 1 scns 0 eo d
= 8 scns 2 eo d
Reduction of Variation
Variation
Reduce tolerances between current and desired end-state Track variation back to its source Occurs in all natural and man-made processes If variation is not measurable, there is an insufficient measurement system
Not Applicable 25-40% of Sales 15-25% of Sales 5-15% of Sales <1% of Sales
Reduction of Variation
Waste Reduction
Reduce
Buy in bulk to reduce the amount of packaging (Bulk Vegetables, IQF Proteins)
Reuse
Water (Ozone), Food (Commodities that may drop during dispense on conveyor)
Recycle
Packaging Materials (i.e. Cardboard Boxes, Hog Farms, Trays, Water/Grease Mixes)
Risk Failure
3 Factors
Severity Consequence of the failure should it occur Occurrence Probability or frequency of failure occurring Detection Probability of the failure being detected before the impact of the effect is realized
10 Steps to an FMEA
FMEA Example
Conclusion to FMEA Powerful Tool When Utilized Properly Must be Understood Once organizations fully understand and commit to the FMEA process, $ Savings and Product and Process Improvements
The best people in the industry with outstanding work ethics, making excellent products and taking great care of our customers
Executive Summary
Objectives Increase First Pass Quality from 91% to 99% by Jan 2011 Reduce Holds by 10% each quarter Methodology Determine V-line process for Thick/Thin issues while implementing specifications for liquid ingredients Determine if target solids are accurate or need to be revised with R and D Train all personnel on V-line process and create manual Determine proper PM's for votators (i.e. Blades, flush outs) Measure initial viscosity and temperatures for correlation vs 24 hour viscosity Determine possible equipment replacement and/or upgrades
Define
Define
Define
Objective
Implement specifications same SIPOC Louisville to begin as Denver for liquid ingredients measuring solids for Corn Syrup, Sweetener, and Combined Liquid at Syrup Mixing Kettle Created step by step process SIPOC, Process Flow Map map Proces created along with s Flow Written Process Steps Diagra m Identified Process Gaps for SIPOC Proposal to input Inputs such as P112, Palm specifications Shortening, Poly Sorbate, Sodium Proponate, and Solids testing Determine Key Inputs versus C and Found out Piping was Outputs based on Processes E main cause of thin issues Matrix and commodies being in specification could result in thick/thin/grainy issues Determined potential failure modes of Key Processes FMEA Determined action plans to change piping, discuss COA's with vendors, and create V-Line manual with training FMEA Determined 1st batch of product after flush out was thin product
Analyze
Louisville uses Granulated Sugar, Denver uses Liquid Sugar
Analyze
Denver uses a 80/20 % combination of Liquid Sugar to Corn Syrup, Louisville uses 74/26
Louisvilles process uses granulated sugar for the seeding of the sugar crystals Denver makes fondant via high heat cook up (236 F) and then cooled before combined with slurry By default one facility using granulated sugar versus liquid sucrose the ratio of corn syrup: liquid sucrose will not match up
Denver uses ADM for Liquid Sucrose, Louisville uses Imperial Sugar or Sweetener Supply
This ingredient is a commodity and should not vary greatly from supplier to supplier
83% of Holds in Louisville are for Viscosity Denver has wider specs for Viscosity due to different Uses Denvers Spread N Gloss used for donut dipping icing and brownies allows wider spec range Louisvilles Spread N Gloss primarily used for Cake Icings requires tighter spec range Denver specs: Viscosity: 200,000 600,000 cps Louisville specs: Viscosity: 320,000 512,000 cps Louisville has Tighter Standard Deviations for Viscosity
Improve
Action Plans
A c tio n P la n s P ro b le m A c tio n R e q u ir e d S te p s
P o te n tia M ass Fl w e ig h t s Va i e i u l t 1 L o a d C e l l s m a y n o t a l w a yP su rbc eh a sc ec uMr aat se s F l o w M e t e r fo r B u l kd aInt g r end- iaecn ct s r a c y o f l o a d c e l gs r ,a n r ui al al tm In s t a l l j a c k e t e d p i p i n g fr o m s y r u p m i x i n g k e t t l e K eeps p P u rc h a s e ja c k e t e d p ip in g P u rc h a s e ja c k e t e d p ip in g c r y s t a lliz 2t o v o t a t o r s 1 ) In s t a l c o n t in u e 2 ) M in im and kee 3) R educ ar In s t a l l a t i o n o f v o t a t o r s w i t h b y p a1s 0s 0 v pa ol vue 3 In s t a l l s p a r e v o t a t o r s w i t hP bu yr cp ha as s e v as lpv e s e v o t a t o r s O n ly n e e d e d if M G N e w e ll a n d C h e r ry B t h e e x i s t i n g e q u i p m e n t i s n o t s u i t e d fo r In s t a l l c o m p l e t e l y n e w s e t o f v o t a t o r s , p u m p b e in g p r o d u c e d (E x is t in g e q u ip m e n t d e s P u rc h a s e a n d t ria l vo t a t o rs in 1 9 9 8 ) R e d u c t io 4a n d v a lv e s D e n ve r c h e c k s s o lid s o f t h e 8 0 % o f 1 0 0 % m ix L i q u i d S u g a r , 2 0 % o f 1 0 0 Im p ml e i m eC not r n oSl i yd r u ep a, d i n g s t o b e tPa uk rec nh ai ns es l M r ircy r ok m t ot ltei o fo rM e t e r w i t h F l o w % x s r u e n re a d in g s t a k e n a u t o m a t ic a lly A llo w s s 5 a n d t h e n c o m b i n e d s y r u pss a m e c o m m o d i t i e s
Improve
Action Plans
i e D 7 C re y n s v tea r l i z c ao t mo nb i no ef s us Fgy al ru ur s pf ho pr vmuo mts a pit noe rdVs ot eht var eot oru yrgs h6 b aT t rca hi ne isn g a n d s i g n o f f s h e R tes d iumc pe
c o o k e r a n d e n s u re s it is h e a t e d t o 2 3 5 t o 2 3 7 d e g r e e s , L o u i s v i l l e dC oh ee sc kn ot et m hp ee cr ak t ut hr e s a n d e n s u r e a t p r o p e r t e m p e r a t u r e a c S t a n d a r d O p e r a t i n g P r o c Ee nd su ur er e 8 t e m p e r a t u r e a t t h i s sp l ou ir nr yt m i x i n g k e t t l e R e s i d u a l w a t e r a f f e cR t as i st he e p ci po i lno gr af r no dm t ht hi ce k sn ye rsu sp w a r m i n g k e t t l e t o c r e a t e a o f f i n a l p r o d u c t m a k di no gw np w o ad r ud c pt i at cp hp et oa r 3s - wd a ry k v a l v e a l l o w i n g f o r p r o p e r w a t e r r d r a i n a g e d u r i n g f l u s h o u t Vs a l i d a t e T h i n P r o d u c t i s Re el i m u i nc at d 9a n d t h i n 1 )E n s u h e a t tra 2) R edu d e c re a c ry s ta l R e p l a c e s h a f t o n v o t a t o r # 1 w i t h w e l d e d p i n s a n d d 2a 4m as gh E x i s t i n g v o t a t o r s i n RL eo pu l ias cv iel l eh eh aa tv et r ae nx sp fee rr i et un bc e ,d s c r a p e r b l a d e s , a n d r3o ) l l R re q u e s P u r c h a s e s h a f t s , r e p l a c ed at uy bs e a a 1 0 i g n i f i c a n t w e a r a n d b ea ar er i no gu t idn a vt oe td a t o r # 2 R educt
Improve #1
Louisville controls bulk liquid ingredient addition by an air actuated valve which weighs up the product in to the warming kettle through load cells
This is controlled through the PLC
Proposed Solutions
Install individual flow meters for corn syrup, liquid sugar and high fructose corn syrup to ensure accurate amounts of bulk liquids are added to the batch which is vital for final solids of product Possibility of using holding tanks pending flow rate and pressure study of bulk liquid delivery system by Emerson/MicroMotion
Improve #1
Improve #1
Improve # 2, 3, 4, 5
Potential Recommendations
Improve #5
Soluble Solids Target Corn Syrup Liquid Sugar Isosweet (HFCS) Combination of all 82.0 67.5 71.0 Batch 1 81.3 67.6 70.5 68.3 Batch 2 82.0 67.9 69.7 69.1
Improve #6
Make product at high and low end at 2 standard deviations for viscosity and show customer for acceptance Need R and D and Marketing input and buy off
Improve #7
ive e t ta nc en na v re inte P a M
Dt ae
V t t r1 oao
V t t r2 oao
V t t r3 oao
Tim e
Improve #8
Follow Standard Operating Procedures to meet Temperature Guidelines for Cook Up If Rework is Added, Determine SOP for Temperature Changes
Improve #9
Ensure Pipe from Syrup Kettle 1 to Mix Kettle is purged and has no residual water
Currently residual water gets trapped in piping from syrup warming kettle to mixing kettles Affects process/product consistency
Residual water affects the color and thickness of final product making product appears dark and thin
Proposed Solution
Raise piping from the syrup warming kettle to create a downward pitch to 3-way valve allowing for proper water drainage during flush outs
Improve # 9 Ensure
Pipe from Syrup Kettle 1 to Mix Kettle is purged and has no residual water
Eliminate to allow pipe to be directly tied to 3-way valve eliminating residual water
Improve # 9 Ensure
Pipe from Syrup Kettle 1 to Mix Kettle is purged and has no residual water
Removed sweep
Changed pitch
Improve # 10
Existing votators in Louisville have experienced significant wear and are outdated Dawn is the only domestic company serviced by MG Newell that uses the pin style shafts for the votator blades Effect on process/product consistency
Product cannot be properly scraped off heat transfer tube wall Causes product build up resulting in increased cleanouts, growth of crystal structures and further wear and/or damage to the equipment Requires replacement of shaft blades every 30 days along with pins creating extensive downtime
Proposed Solutions
Replace shaft on votator #1 with welded pins and 24 shaft Replace heat transfer tube, scraper blades, and roller bearing in votator #2
Improve # 10
Scored surface
Replace threaded pins with welded pins for longer blades Damage from pins
Improve # 11
PM Schedule
Determine proper frequency for Votator Blade replacement given monthly breakdown , with new or in-spec sharpened blades Pumps, Kettle Blades, etc, are inspected monthly and serviced as needed
Improve
Equipment Repair Costs:
Improvement Costs
Replace Votator 1 shaft: $ 10,000 Replace Votator 2 heat transfer tube: $ 21,000 Replace Votator 2 scraper blades: $ 5,000 Replace Votator 2 roller bearing: $ 200 TOTAL $ 36,200
Potential Recommendations:
Jacketed s/s piping: $ 14,000 Spare votators/valves: $105,000 New set of votators: $175,000 MicroMotion Coriolis Brix meter: $ 9,000
Improvement Savings
Control Plan
QUESTIONS?
Improve
Analyze