P09712 Commercial Roll Line Shrink Reduction
Revision # 0 04/08/09 RIT KGCOE MSD Program
P09712 Commercial Roll Line Shrink Reduction
Test Plans & Test Results
By: Evan DeCotis, Levi Stuck, Joseph Fitzery, Ryan Dennison and Cinthia Sanchez
Table of contents
1. TEST PLAN DEVELOPMENT 3
1.1. Project Background and Purpose 3
1.2. Concept Development Summary and Process Areas Being Tested 3
1.2.1. Value Stream Map 3
1.2.2. Cause and Effect Diagram 3
1.2.3. Areas of Focus 4
1.2.4. Issues from Areas 4
1.2.5. Potential Projects 5
1.2.6. Procedures 6
1.2.6.1. K-Roll Standardization 6
1.2.6.2. Rack Loading/Rack Unloading 8
1.2.6.3. Non-Procedure Item 9
1.2.6.4. Quality Control Defect Sorting 9
1.3. Approval 10
1.4. Preliminary Testing 11
1.4.1. Hamburger Roll Data Collection Sheet 11
1.4.2. Hotdog Roll Data Collection Sheet 12
1.4.3. Pie Charts 12, 13
1.4.4. Joint Bar Charts 13
1.4.5. Hamburger Defect Percentage Bar Chart 14
1.4.6. Hotdog Defect Percentage Bar Chart 14
1.5. Definitions; Important Terminology; Key Words 5
1.6. References 5
2. MSD II WKS 2-3: FINAL TEST PLAN 6
2.1. Data Collection Plan; Sampling Plan 6
2.2. Measurement Capability, Equipment 6
2.3. Test Conditions, Setup Instructions 6
2.4. Sponsor/Customer, Site Related, Requests/Considerations 6
2.5. Test Procedure, Work Breakdown Structure, Schedule 7
2.6. Assumptions 7
3. MSD II – WKS 3-10 DESIGN TEST VERIFICATION 8
3.1. Test Results 8
3.2. Logistics and Documentation 8
3.3. Definition of a Successful Test, Pass/Fail Criteria 8
3.4. Contingencies/Mitigation for Preliminary or Insufficient Results 8
3.5. Analysis of Data – Design Summary 8
3.6. Conclusion or Design Summary 8
3.7. Function/Performance Reviews 8
3.8. References 9
3.9. Appendices 9
· 1. 16 bold capslock, aaa 14, 1.1. 14 bold, aaa 12, 1.1.1. 14, aaa 11, 1.1.1.1. 12, aaa 10
· Insert Ryans procedure
· Update Table of contents
· Get rid of widows and orphans
· explain nomenclature: kroll, proofbox, defect types, shrink, what else?
This Test Document lists the processes and categories by which you are going to verify your final design. Testing needed to prove your project meets specifications. These specifications may be categorized into features, functions and performance. You may need to modify key milestones to apply to the specific demands of your project. The plan should be understandable by an engineer not familiar with the project.
Inclusive of both the systems specifications and specifications within and between the major sub-systems. Particular attention should be paid to the interfaces between the sub-systems since different team members may be testing each.
The test needs should be easily comprehended and documented based on MSDI.
The important components of the Test Plan and later Final Test Plan are:
1. What you’ll test (and what you won’t test)
2. How you’ll test: equipment and materials needed, test configurations and procedures, pass/fail criteria
3. Responsibilities and the approval process
4. Risks and contingencies
These elements can be integrated or rearranged to match project characteristics. It may be more helpful to include traceability information (mapping of tests to specifications and, if appropriate, to requirements and functions).
For each specification or feature there is a defined test method or procedure, and pass/fail criteria to demonstrate compliance with the specification or feature. Cut & Paste the team’s specifications then add Pass/ Fail Criteria.
A more detailed content which can be organized including some or all of the following. This portion of the test plan will grow and change as your design grows and changes so revisit periodically. More detail may occur with the Final Test Plan section.
1. Tests (list or table): test # and name; test description.
2. Traceability or verification matrix (table): specification # and brief description; system component embodying the spec (optional).
“how” the team will test and collect results. That is, list specific methodologies to verify systems specifications and any detailed sub-system specifications. This portion of the test plan may need to be revisited once testing begins as clarify of testing needs begins.
List of tests to be performed (indicate test # and name, test description and so on). Specification # and brief description, system component, test #, test date field (start/stop dates may be needed), pass/fail or test result field (verification), remarks or actions needed if test failed and signoff.
More advanced testing becomes more formal requiring good documentation. Define this plan within the team and then share with your Guide for potential feedback. Again, focus on how the team plans to test.
Each area must be tested as a standalone unit by applying the possible input sequences and measuring the output response and confirm with the expected response.
PLAN, EXECUTE, CHECK Populate the templates and test processes established in Final Test Plan. These elements can be integrated or rearranged to match project characteristics or personal/team preferences.
P09712 Commercial Roll Line Shrink Reduction
Test Plans & Test Results
1. TEST PLAN DEVELOPMENT
1.1. Project Background and Purpose
1.1.1. Commercial Roll Line Shrink Reduction is sponsored by Wegmans. The project goals are to decrease the amount of wasted dough and baked rolls. Wegmans estimates between 5% and 10% are lost on a typical day of production on this line. We will be responsible for analyzing, suggesting, implementing, and recording the overall results of our actions.
1.1.2. The objective of the Commercial Roll Line Shrink Reduction project is to identify waste associated with defects and reduce it. Other objectives include implementing flow, transforming current operations to lean processes, developing metrics, and researching and updating outdated bottleneck equipment.
1.2. Concept Development Summary and Process Areas Being Tested
1.2.1. Value Stream Map showing line flow:
1.2.2. Cause and Effect Diagram based on observations on the line focused on six major areas: people, information, environment, processes, machines and material:
1.2.3. Three Areas of Focus were chosen based on data collection figures and analysis of defect sources/analysis of project feasibility. Defect sources were assigned:
1.2.4. Issues regarding three main areas of focus grouped by previous cause and effect categories:
1.2.5. Potential Projects brainstorm session and also originated from 1.2.4.:
1.2.6. Three proposals were presented to costumer developing in three main procedures and one non-procedure extra development:
1.2.6.1. K-Roll Standardization: Queues were forming between K-Roll and Proof Box and between Proof Box and Oven. Calculations were made and it was discovered that there are three bottleneck sources for all 27 different products run on the line: Oven speed, Bagger speed (Sort and Package Area) and K-Roll Speed. Procedure will standardize speeds that both older and newer K-Roll machines need to be run to avoid queues and over proofing by setting up speed chart on K-Roll area, therefore reducing 30% of defects.
1.2.6.2. Rack Loading/Rack Unloading: Order in which racks are loaded or unloaded is non-existent; this causes some pans to be queuing on the rack longer than others, creating defects. Order set takes into account food grade rules. Procedure will also set number of pans loaded on each rack relating it to multiples of number of pans that fit across oven on each loading. In addition, procedure will attempt to mechanize the number of racks loaded into each Proof Box door as a way of proofing time tracking mechanism. A 10% defect reduction is estimated.
1.2.6.3. Non-Procedure Item: Observations and analysis show that pans undergoing extreme situations in the Proof Box usually result in dry spot defects. Previous observations showed entire pans were defective (dry) this is what triggered the procedure Covers will be attached to top of racks to minimize extreme conditions in top of rack due to Proof Box’s heat vent location.
1.2.6.4. Quality Control Defect Sorting: Observations and data collection lead to defect type categorization. There was a lack of consistency in defect classification and ambiguity regarding what a “good” product entails. Procedure will implement visuals on floor to avoid subjectivity and clarify what should be considered a defect and what should be considered a good product via pictures. A stand will be installed taking into consideration Ergonomics, Human Factors and easiness of manufacturing.
1.3. Approval
Approved by:
P09712: Commercial Roll Line Shrink Reduction 1
Revision # 0 04/08/09 RIT KGCOE MSD Program
Project Leads:
Engineering Team:
Faculty Guide:
Teaching Assistant:
Primary Customer:
Evan DeCotis ()
Levi Stuck ()
Ryan Dennison ()
Joseph Fitzery ()
Cinthia Sanchez ()
Prof. John Kaemmerlen
Phil Bryan
Wegmans
P09712: Commercial Roll Line Shrink Reduction 1
Revision # 0 04/08/09 RIT KGCOE MSD Program
1.4. Preliminary Testing
When 1 K-Roll is running, defect rate of 3 to 6%, when 2 K-Rolls are running, defect rate of 8 to 12%
1.1.1. Hamburger Roll Data Collection Sheet
1.1.2. Hotdog Roll Data Collection Sheet
1.1.3. Pie Charts
1.1.4. Joint Bar Chart
1.1.5. Hamburger Defect Percentage Bar Chart
1.1.6. Hotdog Defect Percentage Bar Chart
1.1.7. Other Data
1.1. Test Strategy
1.1.1. Costumer Needs
1.1.2. Engineering Specifications
1.1.3. Assumptions:
1.1.3.1. Test Plan was developed based on the assumption that all implemented procedures are being followed.
1.1.3.2. It is to be taken into account that there are two kinds of testing, verification of defect reduction from measures taken and behavioral tests to see if procedures are accepted and used by personnel and management.
1.1.3.3. Environmental conditions do not play as significant as a role as queues and overproofing.
1.1.4. Test Plan:
All procedures were developed related to engineering specifications. The Marginal Value and Ideal Value will serve as our pass/fail criteria. Main focus is to meet Engineering Specifications rated as a 9. Our Minimum goal is to reduce defects by 20%. Test Plan will be targeted to each procedure. (1.2.6.1-1.2.6.4)
1.1.5. Test Equipment available
N/A
1.1.6. Test Equipment needed but not available
N/A
2. FINAL TEST PLAN
2.1. Data Collection Plan; Behavioral Test Plan
2.1.1. Data Collection Structure
Procedure testing will be done in the form of Defect Data Collection at the End of the line and in the form of performance management. Audits/Checklists will be implemented for testing behavioral response to procedures. Objective is improvement in a small amount of time. All data collection will be compared to preliminary data test results (1.4) to confirm 20% defect reduction.
2.1.2. Phases of Testing
Phases are set by Procedure (1.2.6.1-1.2.6.4)
2.1.2.1. Testing of K-Roll Standardization Procedure
K-Roll machine speeds will be set so they don’t exceed charts (1.2.6). Data collection will be performed at the end of the line in 30 minute sessions in four different days. Test for setting equal speeds and for having the newer K-Roll machine run faster than the older K-Roll machine.
It is assumed that the older K-Roll machine creates more defects than the newer K-Roll machine, so that is the reason for putting the largest load on the newer machine. Data from equal speed setup will also help verify this assumption.
K-Roll machine speed setting capability (minimum, maximum and increments within that range) is being investigated at this moment.
Initial Checks:
· Bagger should read 0 packages, beginning of the run
· Make sure oven is set for 8 minutes baking time
After K-Roll starts to run:
· Make sure 6 pans for ham and 5 for hots are put in the oven. No less
· Mark the switch in K-Roll production speeds on racks/trays/rolls so we can find them again
While waiting for the product to flow through line, observations must be recorded regarding the effect these newly set k-roll speeds have on:
· Queues between K-Roll and Proof Box
· Queues between Proof Box and Oven
· Bagger speed
· Oven Loading pace effect
Also implement checklist and tailor it to the most advantageous way. Preliminary checklists:
If "No" column has a check there will be a coresponding comment
Log book will be used to anlysis and resolve and issues/feeback provided by employees. Needs to be formalized.
2.1.2.2. Testing of Rack Loading/Rack Unloading Procedure
Observations will be made to see it procedure is been followed by line workers and its being supervised by management team. Also observations need to be made to try to incorporate current order chosen by each worker.
2.1.2.3. Testing of Non-Procedure Item
Preliminary testing is not available for this item. Observe if entire pans are defective in the QC sorting area.
2.1.2.4. Testing of Quality Control Defect Sorting Procedure
Picture checklist used in process of taking photographs to compile visual aid.
Observations will be made to see it procedure is been followed by line workers and its being supervised by management team. Look for feedback regarding:
· Stand Design: Stand Height, easiness to flip laminated pages, easiness to remove. Visual does not interfere with line worker movements and view of conveyor area vicinity.
· Visual Dimensions: Shape rectangular vs. square, height of visual easy to depict without changing eyesight line.
· Defect category and roll type grouping: Feedback collected regarding if photographs cover every possible most common defect per roll type (defects depicted should have an occurrence of 10% or more). Also verify that in cases when the images were grouped to a similar category, defects are actually similar, or if roll type needs its own visual.
· Visually optimal: Verify layout colors, photograph sizes and photographs subtitles are optimal.
2.1.2.5. Integration
Since all tests are verified in the QC Sorting line. It will be difficult to quantify which procedure reduced which amount of defects. K-Roll speed settings can be tested immediately. Covering racks will need some time since covers need to be permanently physically attached to racks. Goal is in terms of overall defect reduction, but there is the possibility that, if time permitting, data can be collected again and results can be compared to see what fraction was the rack top covering action.
2.1.2.6. Reliability (wks 15-20)
If there is a specification, such as a drop test, out of range voltage or some other form of potentially destructive testing, discuss this with your Guide and Sponsor. As an example, this specification maybe waived depending upon the specific customer needs.
• Reliability is the most important characteristic