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
Distance from Tray denester (front of line)
Special Notes
Hours worked per day

Lead person
Directs employees, gives breaks, orders supplies and any other tasks as needed

Can be used to fill short term emergency vacancies

Tray machine operator
Feeds trays into denester
Feeds trays once every 3 minutes. One minute to c

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