Using 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 as follows:

• 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.