Design Proposal Brady Brewer Stephen Eller Michelle Jones - PowerPoint PPT Presentation

Design Proposal Brady Brewer Stephen Eller Michelle Jones David Haury

Outline • Introduction • Business • Communications • Engineering • Radical Ideas • Recommendations • Questions

J-M Farms • Main Facility – Miami, OK • Established 1973 • 5 Satellite Farms • White & Portabella Mushrooms • Cover OK, TX, AK, MS, NM, KS, MO, IA. Photo Available at : http://www.jmfarms.com/index.html

Problem • Problem Statement “Our project is to improve the harvesting and packaging efficiency at J-M satellite farms. The most important factors affecting design are: ergonomics, cost effectiveness, maintenance, and simplicity.” • Mission Statement “To provide a quality solution to improve J-M Farm’s packing efficiency.”

Project Description • Improve efficiency and quality of mushroom packaging process • New cart was suggested • We examined the entire packaging process • Process Flow • Machine Design

Current Process Diagram courtesy of J-M Farms.

Current Process

Industry Analysis • Premium goods dominate the industry – Emphasis on quality – Consumer behavior • Industry similar to Tomatoes – Growth in the recent past

Competitive Analysis • Internal Competition – Among pickers and processes • External Competition – Regional – National • Specialization seen amongst the industry

Competitive Analysis • Monterey Mushrooms Photo Available at: http://www.montereymushrooms.com/overview.htm

Proposed Business Plan • Executive Summary – Overview of business – Roadmap to follow • Industry Analysis • Competitive Analysis – Emphasis on Internal Competition for picking process

Proposed Business Plan • S.W.O.T. Analysis • Marketing Strategy – Will includes Communications plan – Market saturation versus Market Penetration • Conclusion

Business Plan Impact Photo Available at : http://www.flashbackinfo.org/images/Walmart_New_Logo.png

Proposed Financial Analysis • Activity Based Costing – What is it? – Why would you use it over other methods? • Keep costing for picking process the same • Identify key processes • Cost savings from engineering solution

Communications Plan • Business-to-Business – Mushroom shoppers are valuable to retailers. The average shopping basket with mushrooms is double the value of shopping baskets without mushrooms. • Business-to-Customers – Customers tend to be highly educated and wealthy – Hispanic and Asian purchases increasing – Response to point of source materials

Business-to-Business • Web page – Quality control – Traceability Statistics – Recycling Efforts • Flier or Brochure – Quality control – Traceability Statistics – Recycling Efforts – Next Day Service

Business-to-Customers • Web page – Recipes – Storage and handling procedures – Quality control – Traceability Statistics – Recycling Efforts • Recipe/Fact Booklet Label – Recipes – Storage and handling tips – Quality control – Traceability Statistics – Recycling Efforts Photos Available at: http://www.jhbertrand.com/cs_promotionalnut.html

Business-to-Customers • Recipe Cards – Recipes – Storage and handling procedures • Fact Cards – Nutritional facts – Storage and handling tips Photos Available at: http://www.stonewallkitchen.com/Content/images/whl_merch_carousel.jpg http://www.ccicards.com/product-group.aspx?groupID=6

Engineering • Interdisciplinary Problem – Food Handling – Industrial Engineering / Ergonomics – Mechanical Design

Engineering Concepts • Industrial/Ergonomic Ideas – 1. CPM Weighing Station at Satellites – 2. Packing Line at Satellites – 3. Redesign Packaging Process at Main Farm – 4. Redesign/Alter Slicing Line at Main Farm – 5. Temperature/Time/Handling Study

Ergonomic/Industrial Ideas Packaging Line at Satellites PROS: • Mushrooms are ready for shipment at satellites • Decreased work load at main facility • Increased space at main facility (focus on slicing) • Test feasibility of a streamlined process CONS: • Heavy initial cost for satellite • Substantial space requirements

Ergonomic/Industrial Ideas Redesign Packaging Process at Main Farm PROS: • Increase Efficiency • Eliminate redundant processes • Mitigate loss CONS: • Adjustment required of employees • Potential production shut down

Ergonomic/Industrial Ideas Temperature/Time/Handling Study

Ergonomic/Industrial Ideas

Engineering Concepts • Mechanical Design Ideas – 1. Picker Cart with Scales – 2. Packaging Cart (using snap-on lids)

Mechanical Design Ideas Picker Cart with Scales PROS: • Pick by weight, not volume • Better quality, reduced handling • Shorter time to package CONS: • Less Flexibility with increased size • Large capital investment • Increase picker work load

Mechanical Design Ideas Weighing/Packaging Cart (Snap-on lids) PROS: • Ready for shipment at satellites • Increased shelf life • ‘One Touch’ produce • Less work load at main facility CONS: • Size of cart will likely double • Heavy capital investment • Increase picker work load substantially • May require alternate RPC

Radical Ideas • Team Pay • Value-Added Products • Sell Mushrooms by Count, not by Weight

Team Pay • Current system pays picker by the pound and packing line workers at an hourly rate • “You do your job, I do mine” • Mushrooms get dropped

Team Pay • Team would get paid based on what goes onto the truck • Increase motivation to decrease waste • Foster teamwork among the members across the different steps in the harvesting process

Value Added Products • Sautéed • Fried • Battered Photo Available at: http://www.poboyexpress.com/menu/foodimg_lg/fried_mushrooms.jpg

Sell Mushrooms By Count • Mushrooms sold in stores today must meet a certain minimum weight • Leads to wasted effort in weighing the package multiple times • Pack by number of mushrooms inside, not by a goal weight • Print a sticker to display the weight of package so product could still be sold by weight, if mandated

Sell Mushrooms By Count • Process of packing is simplified because the picker can do it with minimal equipment • Scale could even be dropped if mushrooms are sold purely by count • Package directly after picking • Highest quality and freshness

Sell Mushrooms By Count • Some fresh tomatoes are already being sold by count • Customers can easily see the quality product Photo available at: http://www.linpac.com/PageFiles/312/About---tomato-tray.jpg

Sell Mushrooms By Count Photo available at: http://www.linpac.com/PageFiles/179/Library/Tomato-tray-collage.jpg

Project Recommendation 1. Redesign Packaging Floor 2. Temperature/Time/Handling Study 3. Weighing / Packaging Cart (Snap on Lids) 4. Combination

Questions?

Thank You!