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WHITE DELI SUB PRODUCTION PROCESS IMPROVEMENT

This document outlines a structured approach to improve the production process of White Deli subs, emphasizing efficiency and quality. While the product remains popular and well-regarded in terms of quality, current observations reveal issues such as a low production rate and remixing challenges. By implementing a clear work sequence and improving mixing and scaling processes, we aim to raise overall production quality and reduce scrap rates. Key solutions include refining timing, standardized processes, and revising remix policies to ensure optimal outcomes.

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WHITE DELI SUB PRODUCTION PROCESS IMPROVEMENT

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  1. WHITE DELI SUB PRODUCTION PROCESS IMPROVEMENT SOLUTION APPROACH May 21st 2012

  2. BACKGROUND PROS • Wonderful Product • Good Quality • Best Selling • Good Production • CURRENT OBSERVATION • Low DoS (Missing Quality) ! • Remix Type and Rate • Mixing Pace • Breakdowns

  3. SUPPORTING DATA • Average Mixing Pace : 14mn30sec vs11mn37sec (Divider Time) • AverageQ1-2012 DoS11vs14 (Required for best quality) • Average remix rate 4.65% • 20% over 10% Dough Weight • Average Scrap rate 0.95% • Average Moline Line Impact 2.00% • Average Scaling Time 4mn • Average Loading Time 1mn

  4. SOLUTION FLOW Implementing work sequence • Process flow plan: work sequence and timing • Standard Work Diagram: walking path • Job Aid : training and reference

  5. Process Flow Plan • Ingredients Scaling • Ingredient Loading • Auto-Delivery and Mixer Starting • Picking up remix • Mixing process • Unloading Mixer • Dividing Time • Idle Time

  6. Standard Work Diagram

  7. Job Aid

  8. Snapshot Audit • Using Mixer timers as reference • Link key process steps to timers reading • Read timer to assess pace keeping • Get back on pace after every unplanned gap

  9. Remix Policy • Providing new Remix buckets (max weight 53lb) • Put additional doubles into trash • No remix at Divider • Weight and record trash at the end of every session

  10. Thanks for your attention

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