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Sarah Rubinton
Will Reid
Abhishek Sinha
Gian Calvesbert
Kobi Magnezi
AGENDA
Introduction and problem statement
Observations and Constraints
Process Flow Analysis
Capacity Utilization and Recommendations
After analysis and learning
INTRODUCTION
• Tribe Mediterranean foods, based in Taunton, MA
• Established in 1994 and is a subsidiary of Osem/Tivall (nestle Israel)
• Products: Mediterranean food including several flavors of hummus and
meat substitutes.
• Veggie patch was an independent company and was acquired by tribe
in 2008 to penetrate the us market for chilled and frozen meat
substitutes ($600m market)
VEGGIE PATCH
Meat substitutes market
• 3rd place market share in the meat
replacement market
• distribution channels: traditional
supermarket and club
marketplaces, including BJ’s
wholesale club, Sam’s club, and
Costco
OBSERVATIONS AND CONSTRAINTS
• OBSERVATIONS PERFORMED ON APRIL 5 FROM 8 A.M. TO 12 P.M.
• FINAL PACKAGING PROCESS
• MEAT REPLACEMENT PATTIES
• TWO DISTINCT PRODUCT SIZES OBSERVED
• LIMITATIONS
PROCESS PHASES
Supply from Czech RepublicSupply from Czech Republic
Filling retail/club
packages
Filling retail/club
packages
Flapper
Metal detector
& Scaling
Jam clearance
table
Jam clearance
table
Label alignment
inspect
Label alignment
inspect
Upper & lower labeling
(x2)
Preparing package and
date-labeling
Expiration date
printingTasting QATasting QA
Boxing for retail/clubBoxing for retail/club
Tapper (x2) Pallet loading InventoryInventory DistributionDistribution
U-Shape
•Convert the
line from an
L shape to
a U shape
routing
•Reduce idle
workforce
1
RECOMMENDATIONS
RECOMMENDATIONS
Prevent jams
•Reconfigure the
conveyor guiderail
system
•Prevent jams with
simple visual guides
Visual signals
•Build in more visual
signals to alert
workers to issues and
jams along the line
•Improve
communication and
reduce waste
2 3
AFTER ANALYSIS AND LEARNING
• HARD TO IDENTIFY AREAS OF IMPROVEMENT FOR
CONTINUOUS PROCESS
• MINOR MISALIGNMENT OF PACKAGES CAN CAUSE PRODUCT
BLOCKAGE ON PRODUCTION LINE AND LOSS IN EFFICIENCY
• SETUP TIME AND CHANGEOVER TIME ARE A MAJOR SOURCE
OF TIME LOSS
• CERTAIN MINIMUM PEOPLE ARE NEEDED TO BABYSIT
MACHINERY EVEN FOR AUTOMATED PROCESSES
• TRYING TO INCREASE THROUGHPUT BY INCREASING
PRODUCTION LINE SPEED CAN CAUSE PROCESS FAILURE
(EG. PRODUCT BLOCKAGE, HUMAN ERROR) AND LEAD TO
LOST TIME

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Operation Management Field Project - Tribe

  • 1. Sarah Rubinton Will Reid Abhishek Sinha Gian Calvesbert Kobi Magnezi
  • 2. AGENDA Introduction and problem statement Observations and Constraints Process Flow Analysis Capacity Utilization and Recommendations After analysis and learning
  • 3. INTRODUCTION • Tribe Mediterranean foods, based in Taunton, MA • Established in 1994 and is a subsidiary of Osem/Tivall (nestle Israel) • Products: Mediterranean food including several flavors of hummus and meat substitutes. • Veggie patch was an independent company and was acquired by tribe in 2008 to penetrate the us market for chilled and frozen meat substitutes ($600m market)
  • 4. VEGGIE PATCH Meat substitutes market • 3rd place market share in the meat replacement market • distribution channels: traditional supermarket and club marketplaces, including BJ’s wholesale club, Sam’s club, and Costco
  • 5. OBSERVATIONS AND CONSTRAINTS • OBSERVATIONS PERFORMED ON APRIL 5 FROM 8 A.M. TO 12 P.M. • FINAL PACKAGING PROCESS • MEAT REPLACEMENT PATTIES • TWO DISTINCT PRODUCT SIZES OBSERVED • LIMITATIONS
  • 6. PROCESS PHASES Supply from Czech RepublicSupply from Czech Republic Filling retail/club packages Filling retail/club packages Flapper Metal detector & Scaling Jam clearance table Jam clearance table Label alignment inspect Label alignment inspect Upper & lower labeling (x2) Preparing package and date-labeling Expiration date printingTasting QATasting QA Boxing for retail/clubBoxing for retail/club Tapper (x2) Pallet loading InventoryInventory DistributionDistribution
  • 7. U-Shape •Convert the line from an L shape to a U shape routing •Reduce idle workforce 1 RECOMMENDATIONS
  • 8. RECOMMENDATIONS Prevent jams •Reconfigure the conveyor guiderail system •Prevent jams with simple visual guides Visual signals •Build in more visual signals to alert workers to issues and jams along the line •Improve communication and reduce waste 2 3
  • 9. AFTER ANALYSIS AND LEARNING • HARD TO IDENTIFY AREAS OF IMPROVEMENT FOR CONTINUOUS PROCESS • MINOR MISALIGNMENT OF PACKAGES CAN CAUSE PRODUCT BLOCKAGE ON PRODUCTION LINE AND LOSS IN EFFICIENCY • SETUP TIME AND CHANGEOVER TIME ARE A MAJOR SOURCE OF TIME LOSS • CERTAIN MINIMUM PEOPLE ARE NEEDED TO BABYSIT MACHINERY EVEN FOR AUTOMATED PROCESSES • TRYING TO INCREASE THROUGHPUT BY INCREASING PRODUCTION LINE SPEED CAN CAUSE PROCESS FAILURE (EG. PRODUCT BLOCKAGE, HUMAN ERROR) AND LEAD TO LOST TIME