JTM Foods Process Documentation Project

Overview

The problem JTM Foods wants to solve is the lack of process documentation that leads to material and time wastes for the dough mixing station, filing cook platform, and crispy cook platform. The team and JTM decided to focus on the dough mixing area to grasp the root cause(s) and form a successful solution. The team will perform several observations and analyses to correctly document the processes at the dough mixing station.

Objectives

• Create accurate process instructions
• Implement ways to trace bad batches to reduce time and material waste in the dough mixing area
• Help workers feel confident in the job they are doing to reduce turnover in the plant
• Perform root cause studies to improve product quality
• Key business goals: profitable growth, consistent productivity, engage people, superior product and value-added technology

Approach

• The current system was analysed. Important notes about the process flow and work area layout.
• Customer needs, metrics, and project specifications were formed over several meetings with JTM.
• Both value-add and root cause analyses were performed based on observation data collecting.
• Four concepts were generated. A cost analysis, concept screening, and concept scoring were performed to select the final concept.
• The final design includes an SOP document, a training PowerPoint, and four flowcharts.

Outcomes

• Standard Operating Procedure document outlining purpose, safety guidelines, and procedure steps with visuals.
• Flowcharts to implement on the floor as quick instructions and reminders.
• Training PowerPoint to integrate with Alchemy, JTM’s current training platform.