Applying Operational Engineering tools to Consumable Goods Industry

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Information about Applying Operational Engineering tools to Consumable Goods Industry
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Published on April 21, 2014

Author: KhaledMabrouk

Source: slideshare.net

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Presentation on Applying Operational Engineering Tools (LEAN, 6 Sigma, etc.) to Consumable Goods industry

© SustProd Solutions “Processes + People Drive Performance” ReduceOR.com Page 1 Rubber Band Effect Applying OE Tools & Techniques in Consumable Goods Processing Industry Presented by: Khaled Mabrouk Operational Engineering Leader Sustainable Productivity Solutions kmabrouk@ReduceOR.com (402) 213-5135

© SustProd Solutions “Processes + People Drive Performance” ReduceOR.com Page 2 Seminar Outline • Interesting Aspects of Consumable Goods Industry • Examples of OE Applications in CG Industry • Consumable Goods Industry & Bay Area+

© SustProd Solutions “Processes + People Drive Performance” ReduceOR.com Page 3 Presenter Background • B.S. Industrial Engineering • Experience: - Fortune 500 Corporations (Transportation, Mfg) - Consulting Industry - Software Industry - Instructor for WSU & EMU • Additional Activities Include: - Active in various professional organizations - Member of Six Sigma Conference Board - Published 20+ papers - Frequent presenter at professional conferences “I work to learn from many people and I digest all useful information so that I can synthesize a cost-effective easily sustainable solution”

© SustProd Solutions “Processes + People Drive Performance” ReduceOR.com Page 4 Interesting Aspects of Consumable Goods Industry (from an OE perspective) • Work in process can have a limited life span and/or require monitoring • Processing equipment is often cleaned out for product change. This is a type of Set-up Time. • Buffers may need to be cleaned out. For example; - level of setup required varies - product type change in a silo • Numerous application of high speed conveyor lines. Need ease of access to failure points. • Conveyors used for processing (not just for buffering and transportation). • Packaging can be a BEAR Clean Equipment as needed Mixing (Pre-Cooking) Cooking Drying/ Cooling Combining (Post- Cooking) Seperation Packaging Buffer as needed and doable

© SustProd Solutions “Processes + People Drive Performance” ReduceOR.com Page 5 Example Project – Specialty Coffee • Purpose of Project: Evaluate Scheduling Strategy for how to best take advantage of current equipment flow • Biggest Challenge: First attempt at significant use of OE • Benefits Achieved: 1) Identified that the surge buffers in front of process step 3 needs to be increased significantly to facilitate optimization of capability of current equipment flow. 2) Changed the process for making product category B to eliminate the need for increasing the surge buffers 3) This change in strategy was ultimately rolled out to all plants Green Coffee Loading Packaging Lines Grinders Roasters Post Roast Silos Green Coffee Silos Ground Coffee Silos

© SustProd Solutions “Processes + People Drive Performance” ReduceOR.com Page 6 Example Project – Specialty Coffee • Purpose of Project: Evaluate Machine B operational strategy • Biggest Challenge: Current Silo Management process required significant hands-on manipulations • Benefits Achieved: 1) Eliminated the need for building buffers after Machine B 2) Worked with Machine C supplier to incorporate Machine B capability 3) This change was ultimately rolled out to all plants Green Coffee Loading Packaging Lines Grinders Roasters Post Roast Silos Green Coffee Silos Ground Coffee Silos

© SustProd Solutions “Processes + People Drive Performance” ReduceOR.com Page 7 Example Project – Specialty Coffee • Purpose of Project: Develop Generic Plant simulation based tool to prepare for planned operational expansions • Biggest Challenge: Determining level of detail for Generic Plant model • Benefits Achieved: 1) Identified critical operational flow factors for designing a plant 2) Defined relationship between demand and the sequence of adding equipment 3) Multiple new plants worldwide were built along this prescribed sequence Green Coffee Loading Packaging Lines Grinders Roasters Post Roast Silos Green Coffee Silos Ground Coffee Silos

© SustProd Solutions “Processes + People Drive Performance” ReduceOR.com Page 8 Example Project – Consumable Goods • Purpose of Project: Evaluate strategies for managing in-process buffers • Biggest Challenge: Strategy for managing buffers varied for each operator • Benefits Achieved: 1) Eliminated risk of having to put product on the floor 2) Developed formalized strategy for managing process rates without overflowing 3) This change was ultimately rolled out to all plants that make this product Ovens In-Line Buffer Dryer CoaterTumblers Packaging Lines Off-Line Buffer Silos

© SustProd Solutions “Processes + People Drive Performance” ReduceOR.com Page 9 Example Project – Specialty Coffee • Purpose of Project: Evaluate strategies for consolidating two plants • Biggest Challenge: To distill useful information from various opinions • Benefits Achieved: 1) Used data to arrive at decision regarding which plant to roll into which plant 2) Determined how much of currently existing equipment is needed for consolidated operations Ovens In-Line Buffer Dryer CoaterTumblers Packaging Lines Off-Line Buffer Silos

© SustProd Solutions “Processes + People Drive Performance” ReduceOR.com Page 10 Consumable Goods Processing Industry – Bay Area + • Del Mar Food Products • Del Monte • Diamond Food • Dole Fresh Vegetables • Ghiradelli Chocolate Co. • Hostess brands • McCormick & Co. • Monterey Gourmet Foods • Otis Spunkmeyer • Peet’s Coffee & Tea • Sara Lee Bakery • See’s Candies • Sunshine Coffee Roasters There’s more to Bay Area than just Silicon Valley.

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