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

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

Packaging Line at Satellites

Ergonomic/Industrial Ideas

PROS:

• Increase Efficiency
• Eliminate redundant

processes

• Mitigate loss

CONS:

• Adjustment required of

employees

• Potential production shut

down

Redesign Packaging Process at Main Farm

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

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

Picker Cart with Scales

Mechanical Design Ideas

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

Weighing/Packaging Cart (Snap-on lids)

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!