PLANNING AND PRODUCTIVITY
Bakery Layout Development
Advent Design was asked to review
the operations at the baking facility of a regional baked-goods
manufacturer and develop a comprehensive plan for a facility reorganization
and expansion. The facility produces breads, rolls, and other
bakery products for distribution to restaurants and retailers
in a three-state area.
lean manufacturing techniques, Advent Design reviewed the
operations at the facility and developed a value stream
map of the current operations. The value stream map detailed
the production operations and equipment cycle times and
changeover times along with the flow of order and production
information. Using the information gathered, Advent Design
developed a desired future state value stream map, which
identified recommended process changes. New equipment, work
area changes, and workflow were all considered in the desired
future state map. Some of the major changes proposed were
- Convert DOS-based production
planning and shipping programs to an integrated system
using Windows-based software.
- Go to “Product
Family” production when an adjacent building becomes
available for expansion.
- Improve oven reliability.
- Increase the area available
for designated product staging and truck loading.
Advent Design developed
recommended layouts for the new equipment that had been
and was to be purchased as well as for potential expansion
into two adjacent buildings on the same block as the existing
baking facility. Advent Design also worked with the customer’s
architectural firm to develop an estimated cost for the
renovation of the adjacent buildings.
Advent’s report provided
the customer with a blueprint for future expansion and for the
consolidation of operations from other bakeries that they have
purchased. Work to date has been limited to equipment and layout
improvements within the current facility. Expansion is planned
once product demand returns to the higher levels seen previously.