Floor Notes – 9/16/2013 (Bob; Pre-Scaling Process) - Valeria
· Job elements of Pre-Scaling
· Getting ingredients (Bob tries to get all ingredients before starting the scaling).
1.1. Getting containers (white buckets).
1.2. Refilling ingredient containers.
- Scaling (Bob tries to get all scaling before mixing)
2.1. Cleaning (Total time and time per batch)
- Mixing
- Washing (Sometimes Bob washes the mixer, it’s faster than waiting for Sanitation)
- Mixing
- Waiting/Storage
- Set up machine for dividing (Does it happen simultaneously?) 1pm
- Dividing (cycle info)
- Freezing (30 mins)
- Packaging (standard)
· Line Lead, Bill, might ask to add additional batches depending on time availability. This implies getting more ingredients scaled.
· How are the ingredients storage arranged? (Spaghetti diagram)
· Get APV Cookie Oven, Polin Oven Tunnel Sheet)
· Bob looks at this document to have an idea of when mixer will be available. The document has information about commercial cookies. Example, how long will they be running.
· Get amount of overtime in the past month? Two months? Year?
· Fridge/freezer space is available!
Floor Notes – 9/16/2013 (Bob; Pre-Scaling Process) – Richard & Valeria
· Bob only one scaling it. Cannot scale until commercial scaling is done.
· Usually only do one type/day. Maximum: two types/day.
· Can you scale today & mix tomorrow?
o Sometimes have to scale whole week ahead. Try to do big mixes a day ahead.
· How many types of cookies are there?
· How long do you have to wait for commercial cooking to finish scaling?
· Bob thinks need 10 more troughs to do things properly.
· Bob only does mixing and scaling.
o He sometimes mixes for the commercial line.
· Jose – based off schedule, how do we know how many times the mixer is used?
o Schedule only shows for dividing. Conversation that mixer and team leader will do.
· Time
o Transporting to Scaling Area
o Scaling – start-to-finish of one mix
§ Butter cutting and weighing
· Clean butter knife
· Moves
· Humidor room – have to do extra mixing for butter when frozen
· Ergonomics of cutting!
· No space for butter storage on floor.
o Cleaning of Mixer
· Sugar, Butter – 50 lbs.
· Scaling (started at 12pm)
o Mix sugar, baking soda, & cream of tartar (23 lbs)
o (200 lbs done separately) + 14 + 5.6 + 3.4
· Scan each “job” and scan each material.
· OSHA rule – can’t life more than 50 lbs at a time.
o Lifted 59 lbs. 36 lbs. + 23 lbs. = 59 lbs!
· All workers in this specific area (pre-scaling & mixing) seem to be cross-trained.
· V-MAG machine used w/ “sheet doughs”
o Used for cutting off pie crusts before, cleaned after.
· Dividing machine operators comes in at 1pm and sets up machine & cleans. Doesn’t wait for sanitation.
Floor Notes – 9/31/2013 (Bob; Pre-Scaling Process, Mixer, Commercial Divider) - Bridget
· Pallet filled with all partials placed up next to mixer
· All full ingredients places whole pallet by mixer
· Workers say Commercial Divider takes 23-25 minutes to divide 1 batch 40-45 minutes to divide 2 batches
· Workers say Commercial line takes half hour to get cookies from divider to packaging
· Workers say Commercial line takes half hour for sanitation to clean line
· Sanitation was already there when mixer was done
· Divider still has some old dough from last batch, all is garbage for first bit of run
· Frozen cookies will run sub shop and meltaways. Meltaways are being mixed in the pie room mixer
· Bill (line leader) jumps in if packaging is running behind
· At 1pm the mixer still needs to make peanut butter dough
· Divider needs to be cleaned before peanut butter and dies switched over
· Frozen cookie troughs are all around in the way waiting
· Do they ever mix up what’s on the pallet and add to much ingredients? Should each pallet just have what goes in that batch?
· The mixer puts square green liquids buckets onto mixer stand by hand
· Wash dough scraper in hand wash sink
· While mixer runs workers open all containers, move away empty pallets
· The divider worker from frozen cookie line helps with commercial cookie mixing
· When using smaller mixer, can scale right into bowl
· Oven temp changes when switching cookie types
· Flour, sugar, shortening all sit on pallets beside the mixer
· Have a pre scale rack, all partials sitting on a pallet
· When using the mixer in the pie room the worker must stand by it and manually increase the speed because the bowl is so small it over flows if speed is too high
· Does not recycle cardboard
· Needs garbage emptied more often
·
Floor Notes – 10/1/2013 (Pre-Scaling Process, Mixer, Commercial Divider) – Bridget and Richard
· Bob thinks that there is no chocolate chips even though in the computers inventory it says there is. He goes to check the warehouse, not there. Goes to the shipping guys they haven’t gotten it in. Goes to team leader and tells him there is no chocolate and suggests that they run ultimate cookies as it is planned for tomorrow and uses a different type of chocolate. Says they can then do sub shop tomorrow once the chocolate comes in. Line leader says ya that sounds fine.
· Bob is the one that made decision to change the type of cookie.
· Bob must personally run around the building to check for material
· Mixer used by fig guys (a commercial cookie made on Wednesday) tie up the mixer and did not communicate with Bob that they would be using it.
· Pre scaled ingredients just sitting out with no label on them
· Macaroons use paper on conveyor line
· Bob must move ingredients from around mixer that he won’t use and put his ingredients up
· Macaroon dough too runny, must put back into mixing bowls and mix. The dough was not mixed again before being put into the troughs which makes it runny.
· In past someone would prescale and put all ingredients up by mixer. Now Bob must come in and do it all.
· Bob called forklift guy to help, he didn’t show up, so Bob must collect it all himself, he should not have to collect it all himself
· Bob doesn’t set the troughs out early because sprinkles blow into troughs and stick to the spray
· Should run commercial cookies with butter on a different day than frozen line with butter so there can always be enough that is warm for mixing
· How is the mixer set? On a timer?
Floor Notes – 10/1/2013 (Jose Meeting) – All
· 3 Am Mixer comes in
· Sam the prescaler for commercial scales the night before and comes in at 4am
· Commercial Line has separate prescaler and mixer as well as a helper
· Sanitation guy must come if it’s an allergen type of cookie, rest of cookies can be washed by mixer worker, sometimes don’t even need to clean it.
sanitation after nuts, pecans, walnuts
· Ingredients stored by what condition they must be stored in. Production and material handlers decide where to move ingredients. Ron Amic (material handler supervisor) Mark Fitzgerald (Receiving supervisor)
· Team Leader will work with Kathy to make changes of schedule
· Pre scaled eggs can sit out for an hour
· Sheet Cookies can sit out over night
· Macaroons must sit out over night, must be mixed one more time right before dividing
· All rest of cookies should be made the day of
· Team leader should let the scheduler know when late, together should decide which to cut short, this does not happen, team leader decides on own
· Want a matrix of which cookies can be run after one another
Floor Notes – 10/4/2013 (Pre-Scaling Process, Mixer, Commercial Divider) – Bridget
· X-ray machine tested every half hour, stops whole line when it finds metal item
· Sweet dough mixer can be used
· Sanitation worker gets and empties dumpster
Floor Notes – 10/8/2013 (Frozen Divider) – Bridget
· 2pm decision is made about cutting doughnuts or not
· Pre scalers for commercial get ready for next day and prescale out as much as they can
· Bill says that he asked for a 3rd commercial trough and they said yes, but it hasn’t come
· New dividing machine does not need a paper cutter person
Floor Notes – 10/10/2013 (Mixer, Commercial Divider) – Tyler
· Mixing was delayed 2:30 one run for operator to walk over and fill buckets with water. Would all mixing times be improved if water was run right by mixer or could be put directly in the mixer?
· Try to get time studies of mixing process with 2 people? Compare the cycle time of 1 operator vs 1 operator and a helper.
· Possibility of putting ingredients up on pallet racks by batches, rather than by bulk. For example one pallet would have most or all the ingredients needed for 1 mixer batch.
· Commercial cookie line only has 2 troughs. If 1 is up on the divider and 1 has mixed dough waiting to be divided, there is the possibility the mixer could sit with mixed dough because there is nowhere to dump the mixer. On 10/10 mixer sat 12 minutes waiting for empty trough. Need to find out from Jose if they are already purchasing a third large trough?
· Mixer waited 13 minutes for sanitation to arrive after commercial cookies were done in the mixer.
Floor Notes – 10/11/2013 (Pre scaling) – Bridget
· Need notes/signs on pallets to tell what is precaled on it
· Are there any old mixers/mixers in other areas that are sitting idle at this time?
· Do the macarrons ever get mixed in the large mixer?
· Pre scaler cuts boxes of butter in half so butter softens faster
· Cheese cake line uses the butter in the main room
· Fork lift guy moves ingredients off floor to clean up, ingredients are not the ones needs for the next product and should really be put away
· When starting to divide a new product worker bunches up the dough to signal that it’s a mix and should be dumped
Floor Notes – 10/17/2013 (Mixer, Commercial/Frozen) – Tyler
· Wasted time moving dumpster back and forth to change out pallets on pallet rack. This was magnified by waiting for a forklift.
· Commercial cookie mixer operator cleaned out mixer for changeover to frozen cookies. Bob said sanitation doesn’t start till 3, that’s why he cleaned it out.
o It took mixer operator 8:29 to clean mixer.
· Bobs schedule sheet said that he was making 6 double batches rather than 12 batches. However he mentioned for Dads cookies (what he was mixing) that double batches aren’t possible. So in reality he was trying to make 12 single batches.
· No one covered the mixer while Bob was on break, thus leaving the mixer stalled for 30 minutes.
o Who decides if someone will cover mixer on break?
o Does someone cover the commercial cookie operator breaks?
Floor Notes – 10/21/2013 (Mixer, Commercial/Frozen) – Tyler/Valeria
· Mixer sat full from 1:00-1:45 because both large troughs were in use.
· Frozen cookie production was cut from 8 to 6 to 4 because of high demand for Commercial cookies and spiral availability due to donuts.
· Cookie types that can sit mixed overnight (per Bob) Sugar Sheet Circles, Sugar Sheet, Saber Breton, Dads chocolate chip.
o Kept in Bakery area 2/Cooler # 2
· Mixer cycle time (per Bob)
o 27-35 minutes for sub shop cookies (Most labor intensive)
o 22-25 minutes for ultimate & dads (Least labor intensive)
· Floor stock for commercial cookies, how much and why?
· If spiral doesn’t have availability could we still mix frozen cookies that are able to sit over night?
· Who changes daily production amount of commercial cookies (went from 6-12)
· Bob washed mixer at the end of commercial cookies, took 14 minutes.
Floor Notes – 10/22/2013 (Divider) –Bridget/Richard
· Unifiller machine is not very reliable
· Was not dividing sugar sheet correctly so switched to ultimate
· Called mechanic to get divider to give correct size cookies
· Still need a worker to move sheets from one conveyor to next
· Harder to scoop out troughs while up on divider
· Has to scoop trough out by hand once it’s on the ground
· Need extra person to make sure dough is not in the area the paper cutter comes down
· Has to throw out dough because it has paper in it
· Throwing out dough even though it is fine
· Worker does not take responsibility for jamming up divider, just hangs out while others fix it
· Other worker teaches new kid how to move dough out of the paper cutters way, works slowly with him
· Lots of dough thrown out
· Give new kid an easier job so that paper cutter has less problems
· Need to train new people better