Describe your combinations/elimination below.

Instructions and other info

Additional facts
Each of the four lines are configured and staffed the same way with the same machinery and % utilization. Lines 1 and 2 are in the same part of the plant and from centerline to centerline are 40 feet apart. Trays can be loaded from either side of the line and from the front end of the line. Carton and film machines and case packers can be left or right handed machines meaning they can both be fed between the lines. Component placers are split with two on each side of line. There are cross overs ~every 30 ‘ to move from one side of the line to the other. Lines 3 and 4 are configured in this same manner but are located approximately 150’ from Lines 1 and 2. Job combinations can occur in several different ways.
1. Jobs can be eliminated entirely with proper justification but must be supported by facts
2. Jobs can be combined within the same line.
3. Jobs can be combined between Lines 1 and 2 or Lines 3 and 4. Assume if Line 1 and 2 can combine so can Lines 3 and 4
4. Jobs can be combined between three or four lines.
At no time can an employee be utilized over 100%. When moving within a line assume .5 seconds per foot traveled. If you move 10 feet the travel time would be 5 seconds to new location and 5 seconds return. When traveling between two adjacent lines this also applies. If you must change out gloves assume one minute and if you must change uniform assume 20 minutes. If you move from the Line 1 and 2 area to Line 3 and 4 area assume a minimum of three minutes travel time each way. If a cross over is needed asume an additonal 30 seconds in additon to the time per foot.
When calculating savings assume each line runs 250 shifts per year on 1st shift and 250 shifts per year on second shift. Total of 2000 annual shifts. Assume an average hourly rate per employee is $17.50 per hour with a fringe rate of of 150%.
A video will be provided in D2L with additional details and examples. The jobs I would look at as candidates for improvement are Tray machine area, Film machine related, Case packing and stacking, Carton machine area, Component placers, Prep employees, QA inspectors, Weight control, and any other areas you may think are feasible. Hint: In some areas there may be more than one way to make a combination although one methodology may be better than the other. Also, not all the areas mentioned above have an opportunity with a reasonable chance of success. Make sure to read the info in the Special notes column especially the ones that are color coded.

Line 1

Job # Job title Job description % Utilization Frequency Distance from Tray denester (front of line) Special Notes Hours worked per day
1 Lead person Directs employees, gives breaks, orders supplies and any other tasks as needed 100% varies Can be used to fill short term emergency vacancies 9
2 Tray machine operator Feeds trays into denester 33% Feeds trays once every 3 minutes. One minute to completely reload the magazines. Can be topped off at any time 1 ‘ Cannot handle food products without changing gloves 8.2
3 Component placer Adds component to tray 84% Places a component every 1.25 seconds 12′ Cannot change lines without changing uniform 8
4 Component placer Adds component to tray 84% Places a component every 1.25 seconds 12′ Cannot change lines without changing uniform 8
5 Component placer Adds component to tray 84% Places a component every 1.25 seconds 12′ Cannot change lines without changing uniform 8
6 Component placer Adds component to tray 84% Places a component every 1.25 seconds 12′ Cannot change lines without changing uniform 8
7 Component placer Adds component to tray 84% Places a component every 1.25 seconds 12′ Cannot change lines without changing uniform 8
8 Component placer Adds component to tray 82% Places a component every 1.25 seconds 12′ Cannot change lines without changing uniform 8
9 Inspect for missing component Add to or remove trays with missing components 80% 37′ Cannot change lines without changing uniform 8
10 Line Service Provides materials to the line in various places 80% varies constantly during shift 2′ to 56′ 8.5
11 Line Service Provides materials to the line in various places 80% varies constantly during shift 2′ to 56′ 8.5
12 Film machine operator Reloads film spindle, splices onto existing roll, removes doubles from splice, rotates spindle, removes spent roll, discards spent roll. 25% It takes 2 minutes to perform duties every 8 minutes. The actual splicing and changing of the roll takes 45 seconds and the rest of the time is in set up and support fuctions The total of 2 minutes does not have to occur consecutively. Once the splice is made, the rejects created can be dealt with immediately or before the next splice is made. removal of the old roll and reloading the new roll on the spindle works the same way. 45′ Cannot handle food products without changing gloves 8.2
13 Film machine inspector Looks for loose seals and removes as needed 80% varies constantly during shift 49′ 8
14 Carton machine operator Reloads flat cartons into machine 20% 30 seconds to reload every 150 seconds. Machine can be topped off at any time. The magazine does not have to be completely empty. 56′ Cannot handle food products without changing gloves 8.4
15 Final inspector Removes open, unsealed or damged cartons 60% varies constantly during shift 61′ 8.4
16 Wgt control Continually monitors weights of product, adjusts machine settings as needed, produces control charts for 6 sigma program 75% varies Can be used in an emergency but every minute this job is unfilled it costs you money 8.4
17 Quality Control inspector Checks component weights every 60 minutes, total weights every 20 minutes and verifies day coding information every two hours. Maintains the official USDA complance records for weight. Required to do re checks if weights are too low and place hold tags when needed. (the last two functions are not included in the 42% utilization) 42% varies Must be HACCP certified and tasks are required by law
18 Maintnenance person Monitors the line, makes repairs and adjustments as needed 95% varies Do not combine with anything 9
19 Case packer operator Feeds blank cases into case packer, changes out pallets of blanks 33% Feeds blanks for 1 minute every 3 minutes 90′ The line produces a maximum of 24 cases per minute 8.2
20 Case stacker Stacks finished cases onto a CHEP pallet 55% Stacks one case every 5 seconds. Capable of 20 cases per minute 112′ Can backlog cases for ~ 30 seconds without issue 8.4
21 Case stacker Stacks finished cases onto a CHEP pallet 55% Stacks one case every 5 seconds. Capable of 20 cases per minute 112′ Can backlog cases for ~ 30 seconds without issue 8.4
22 Remove to warehouse Takes finished pallet to freezer 95% One pallet every 3 minutes 120′ to 275′ Reports to warehouse 8.3
23 Prep employee Prepares product for line in remote location 80% 225′ Loads the system at the beginning of shift and adjusts for zero run out at shift end 9.5
24 Prep employee Prepares product for line in remote location 80% 120′ Loads the system at the beginning of shift and adjusts for zero run out at shift end 9
25 Prep employee Prepares product for line in remote location 80% 90′ Loads the system at the beginning of shift and adjusts for zero run out at shift end 8.5
26 Reject worker Reworks or dumps product removed from line 75% 50″ Varies by product. Can be used on other lines if demand is there 8

Line (2)

Job # Job title Job description % Utilization Frequency Distance from Tray denester (front of line) Special Notes Hours worked per day
1 Lead person Directs employees, gives breaks, orders supplies and any other tasks as needed 100% varies Can be used to fill short term emergency vacancies 9
2 Tray machine operator Feeds trays into denester 33% Feeds trays once every 3 minutes. One minute to completely reload the magazines. Can be topped off at any time 1 ‘ Cannot handle food products without changing gloves 8.2
3 Component placer Adds component to tray 84% Places a component every 1.25 seconds 12′ Cannot change lines without changing uniform 8
4 Component placer Adds component to tray 84% Places a component every 1.25 seconds 12′ Cannot change lines without changing uniform 8
5 Component placer Adds component to tray 84% Places a component every 1.25 seconds 12′ Cannot change lines without changing uniform 8
6 Component placer Adds component to tray 84% Places a component every 1.25 seconds 12′ Cannot change lines without changing uniform 8
7 Component placer Adds component to tray 84% Places a component every 1.25 seconds 12′ Cannot change lines without changing uniform 8
8 Component placer Adds component to tray 82% Places a component every 1.25 seconds 12′ Cannot change lines without changing uniform 8
9 Inspect for missing component Add to or remove trays with missing components 80% 37′ Cannot change lines without changing uniform 8
10 Line Service Provides materials to the line in various places 80% varies constantly during shift 2′ to 56′ 8.5
11 Line Service Provides materials to the line in various places 80% varies constantly during shift 2′ to 56′ 8.5
12 Film machine operator Reloads film spindle, splices onto existing roll, removes doubles from splice, rotates spindle, removes spent roll, discards spent roll. 25% It takes 2 minutes to perform duties every 8 minutes. The actual splicing and changing of the roll takes 45 seconds and the rest of the time is in set up and support fuctions The total of 2 minutes does not have to occur consecutively. Once the splice is made, the rejects created can be dealt with immediately or before the next splice is made. removal of the old roll and reloading the new roll on the spindle works the same way. 45′ Cannot handle food products without changing gloves 8.2
13 Film machine inspector Looks for loose seals and removes as needed 80% varies constantly during shift 49′ 8
14 Carton machine operator Reloads flat cartons into machine 20% 30 seconds to reload every 150 seconds. Machine can be topped off at any time. The magazine does not have to be completely empty. 56′ Cannot handle food products without changing gloves 8.4
15 Final inspector Removes open, unsealed or damged cartons 60% varies constantly during shift 61′ 8.4
16 Wgt control Continually monitors weights of product, adjusts machine settings as needed, produces control charts for 6 sigma program 75% varies Can be used in an emergency but every minute this job is unfilled it costs you money 8.4
17 Quality Control inspector Checks component weights every 60 minutes, total weights every 20 minutes and verifies day coding information every two hours. Maintains the official USDA complance records for weight. Required to do re checks if weights are too low and place hold tags when needed. (the last two functions are not included in the 42% utilization) 42% varies Must be HACCP certified and tasks are required by law
18 Maintnenance person Monitors the line, makes repairs and adjustments as needed 95% varies Do not combine with anything 9
19 Case packer operator Feeds blank cases into case packer, changes out pallets of blanks 33% Feeds blanks for 1 minute every 3 minutes 90′ The line produces a maximum of 24 cases per minute 8.2
20 Case stacker Stacks finished cases onto a CHEP pallet 55% Stacks one case every 5 seconds. Capable of 20 cases per minute 112′ Can backlog cases for ~ 30 seconds without issue 8.4
21 Case stacker Stacks finished cases onto a CHEP pallet 55% Stacks one case every 5 seconds. Capable of 20 cases per minute 112′ Can backlog cases for ~ 30 seconds without issue 8.4
22 Remove to warehouse Takes finished pallet to freezer 95% One pallet every 3 minutes 120′ to 275′ Reports to warehouse 8.3
23 Prep employee Prepares product for line in remote location 80% 225′ Loads the system at the beginning of shift and adjusts for zero run out at shift end 9.5
24 Prep employee Prepares product for line in remote location 80% 120′ Loads the system at the beginning of shift and adjusts for zero run out at shift end 9
25 Prep employee Prepares product for line in remote location 80% 90′ Loads the system at the beginning of shift and adjusts for zero run out at shift end 8.5
26 Reject worker Reworks or dumps product removed from line 75% 50″ Varies by product. Can be used on other lines if demand is there 8

Line (3)

Job # Job title Job description % Utilization Frequency Distance from Tray denester (front of line) Special Notes Hours worked per day
1 Lead person Directs employees, gives breaks, orders supplies and any other tasks as needed 100% varies Can be used to fill short term emergency vacancies 9
2 Tray machine operator Feeds trays into denester 33% Feeds trays once every 3 minutes. One minute to completely reload the magazines. Can be topped off at any time 1 ‘ Cannot handle food products without changing gloves 8.2
3 Component placer Adds component to tray 84% Places a component every 1.25 seconds 12′ Cannot change lines without changing uniform 8
4 Component placer Adds component to tray 84% Places a component every 1.25 seconds 12′ Cannot change lines without changing uniform 8
5 Component placer Adds component to tray 84% Places a component every 1.25 seconds 12′ Cannot change lines without changing uniform 8
6 Component placer Adds component to tray 84% Places a component every 1.25 seconds 12′ Cannot change lines without changing uniform 8
7 Component placer Adds component to tray 84% Places a component every 1.25 seconds 12′ Cannot change lines without changing uniform 8
8 Component placer Adds component to tray 82% Places a component every 1.25 seconds 12′ Cannot change lines without changing uniform 8
9 Inspect for missing component Add to or remove trays with missing components 80% 37′ Cannot change lines without changing uniform 8
10 Line Service Provides materials to the line in various places 80% varies constantly during shift 2′ to 56′ 8.5
11 Line Service Provides materials to the line in various places 80% varies constantly during shift 2′ to 56′ 8.5
12 Film machine operator Reloads film spindle, splices onto existing roll, removes doubles from splice, rotates spindle, removes spent roll, discards spent roll. 25% It takes 2 minutes to perform duties every 8 minutes. The actual splicing and changing of the roll takes 45 seconds and the rest of the time is in set up and support fuctions The total of 2 minutes does not have to occur consecutively. Once the splice is made, the rejects created can be dealt with immediately or before the next splice is made. removal of the old roll and reloading the new roll on the spindle works the same way. 45′ Cannot handle food products without changing gloves 8.2
13 Film machine inspector Looks for loose seals and removes as needed 80% varies constantly during shift 49′ 8
14 Carton machine operator Reloads flat cartons into machine 20% 30 seconds to reload every 150 seconds. Machine can be topped off at any time. The magazine does not have to be completely empty. 56′ Cannot handle food products without changing gloves 8.4
15 Final inspector Removes open, unsealed or damged cartons 60% varies constantly during shift 61′ 8.4
16 Wgt control Continually monitors weights of product, adjusts machine settings as needed, produces control charts for 6 sigma program 75% varies Can be used in an emergency but every minute this job is unfilled it costs you money 8.4
17 Quality Control inspector Checks component weights every 60 minutes, total weights every 20 minutes and verifies day coding information every two hours. Maintains the official USDA complance records for weight. Required to do re checks if weights are too low and place hold tags when needed. (the last two functions are not included in the 42% utilization) 42% varies Must be HACCP certified and tasks are required by law
18 Maintnenance person Monitors the line, makes repairs and adjustments as needed 95% varies Do not combine with anything 9
19 Case packer operator Feeds blank cases into case packer, changes out pallets of blanks 33% Feeds blanks for 1 minute every 3 minutes 90′ The line produces a maximum of 24 cases per minute 8.2
20 Case stacker Stacks finished cases onto a CHEP pallet 55% Stacks one case every 5 seconds. Capable of 20 cases per minute 112′ Can backlog cases for ~ 30 seconds without issue 8.4
21 Case stacker Stacks finished cases onto a CHEP pallet 55% Stacks one case every 5 seconds. Capable of 20 cases per minute 112′ Can backlog cases for ~ 30 seconds without issue 8.4
22 Remove to warehouse Takes finished pallet to freezer 95% One pallet every 3 minutes 120′ to 275′ Reports to warehouse 8.3
23 Prep employee Prepares product for line in remote location 80% 225′ Loads the system at the beginning of shift and adjusts for zero run out at shift end 9.5
24 Prep employee Prepares product for line in remote location 80% 120′ Loads the system at the beginning of shift and adjusts for zero run out at shift end 9
25 Prep employee Prepares product for line in remote location 80% 90′ Loads the system at the beginning of shift and adjusts for zero run out at shift end 8.5
26 Reject worker Reworks or dumps product removed from line 75% 50″ Varies by product. Can be used on other lines if demand is there 8

Line (4)

Job # Job title Job description % Utilization Frequency Distance from Tray denester (front of line) Special Notes Hours worked per day
1 Lead person Directs employees, gives breaks, orders supplies and any other tasks as needed 100% varies Can be used to fill short term emergency vacancies 9
2 Tray machine operator Feeds trays into denester 33% Feeds trays once every 3 minutes. One minute to completely reload the magazines. Can be topped off at any time 1 ‘ Cannot handle food products without changing gloves 8.2
3 Component placer Adds component to tray 84% Places a component every 1.25 seconds 12′ Cannot change lines without changing uniform 8
4 Component placer Adds component to tray 84% Places a component every 1.25 seconds 12′ Cannot change lines without changing uniform 8
5 Component placer Adds component to tray 84% Places a component every 1.25 seconds 12′ Cannot change lines without changing uniform 8
6 Component placer Adds component to tray 84% Places a component every 1.25 seconds 12′ Cannot change lines without changing uniform 8
7 Component placer Adds component to tray 84% Places a component every 1.25 seconds 12′ Cannot change lines without changing uniform 8
8 Component placer Adds component to tray 82% Places a component every 1.25 seconds 12′ Cannot change lines without changing uniform 8
9 Inspect for missing component Add to or remove trays with missing components 80% 37′ Cannot change lines without changing uniform 8
10 Line Service Provides materials to the line in various places 80% varies constantly during shift 2′ to 56′ 8.5
11 Line Service Provides materials to the line in various places 80% varies constantly during shift 2′ to 56′ 8.5
12 Film machine operator Reloads film spindle, splices onto existing roll, removes doubles from splice, rotates spindle, removes spent roll, discards spent roll. 25% It takes 2 minutes to perform duties every 8 minutes. The actual splicing and changing of the roll takes 45 seconds and the rest of the time is in set up and support fuctions The total of 2 minutes does not have to occur consecutively. Once the splice is made, the rejects created can be dealt with immediately or before the next splice is made. removal of the old roll and reloading the new roll on the spindle works the same way. 45′ Cannot handle food products without changing gloves 8.2
13 Film machine inspector Looks for loose seals and removes as needed 80% varies constantly during shift 49′ 8
14 Carton machine operator Reloads flat cartons into machine 20% 30 seconds to reload every 150 seconds. Machine can be topped off at any time. The magazine does not have to be completely empty. 56′ Cannot handle food products without changing gloves 8.4
15 Final inspector Removes open, unsealed or damged cartons 60% varies constantly during shift 61′ 8.4
16 Wgt control Continually monitors weights of product, adjusts machine settings as needed, produces control charts for 6 sigma program 75% varies Can be used in an emergency but every minute this job is unfilled it costs you money 8.4
17 Quality Control inspector Checks component weights every 60 minutes, total weights every 20 minutes and verifies day coding information every two hours. Maintains the official USDA complance records for weight. Required to do re checks if weights are too low and place hold tags when needed. (the last two functions are not included in the 42% utilization) 42% varies Must be HACCP certified and tasks are required by law
18 Maintnenance person Monitors the line, makes repairs and adjustments as needed 95% varies Do not combine with anything 9
19 Case packer operator Feeds blank cases into case packer, changes out pallets of blanks 33% Feeds blanks for 1 minute every 3 minutes 90′ The line produces a maximum of 24 cases per minute 8.2
20 Case stacker Stacks finished cases onto a CHEP pallet 55% Stacks one case every 5 seconds. Capable of 20 cases per minute 112′ Can backlog cases for ~ 30 seconds without issue 8.4
21 Case stacker Stacks finished cases onto a CHEP pallet 55% Stacks one case every 5 seconds. Capable of 20 cases per minute 112′ Can backlog cases for ~ 30 seconds without issue 8.4
22 Remove to warehouse Takes finished pallet to freezer 95% One pallet every 3 minutes 120′ to 275′ Reports to warehouse 8.3
23 Prep employee Prepares product for line in remote location 80% 225′ Loads the system at the beginning of shift and adjusts for zero run out at shift end 9.5
24 Prep employee Prepares product for line in remote location 80% 120′ Loads the system at the beginning of shift and adjusts for zero run out at shift end 9
25 Prep employee Prepares product for line in remote location 80% 90′ Loads the system at the beginning of shift and adjusts for zero run out at shift end 8.5
26 Reject worker Reworks or dumps product removed from line 75% 50″ Varies by product. Can be used on other lines if demand is there 8

Answer

Answers and calculations
Describe your combinations/elimination below. If you wish to use excel and show your work use the first three rows and columns b to g as needed. If you wish to use a separate Word or Excel document to attached to dropbox you may do so.

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