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Reduce Cookie Scrap Rate in NW Bakeries

The project aims to reduce the scrap rate of cracked chocolate chip cookies in northwest region bakeries from 15% to 8% by November 2007. Scrapped cookies currently cost $204,400 annually and limit profitability. The team will focus on identifying and addressing the root causes of cracked cookies through tollgate reviews at defined milestones.

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Ed
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11 views2 pages

Reduce Cookie Scrap Rate in NW Bakeries

The project aims to reduce the scrap rate of cracked chocolate chip cookies in northwest region bakeries from 15% to 8% by November 2007. Scrapped cookies currently cost $204,400 annually and limit profitability. The team will focus on identifying and addressing the root causes of cracked cookies through tollgate reviews at defined milestones.

Uploaded by

Ed
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd

Lean Six Sigma Project Charter

Title: Reduce Scrapped Cookies in NW Region

BB/GB: B. Thornton

Business Gap

Financial Impact

Our bakeries scrap approximately 25% of all cookies baked.


Scrapped cookies limit our ability to remain profitable while we
are being pressured to reduce prices by our competitors.
Scrapped cookies have always been an issue and it has
become worse since new ovens were installed. Based on a
Pareto Analysis we will focus initially on the NW Region.

$204,400 in direct savings based on current production rates

Customer
External: Grocery Stores, Consumer
Internal: Regional General Manager
Defects & Metrics
Defects: Scrapped Cookies
Primary: Scrap Rate for Cracked Chocolate Chip Cookies
(CCCC)
Secondary: Returns dues to CCCCs
Consequential: Taste, Chewiness

Problem Statement
The scrap rate due to cracked chocolate chip cookies
in the NW bakeries was 15% for the past 12 months
based on daily scrap reports.

Milestones/Timeline:

Scheduled

Define Tollgate Review:


Measure Tollgate Review:
Analyze Tollgate Review:
Improve Tollgate Review:
Control Tollgate Review:

June 4, 2007
July 9, 2007
August 13, 2007
September 10, 2007
September 24, 2007

Actual
6-4-07

Project Scope/Boundaries:
Process Start: Mix Ingredients
Process Stop: Bake Cookies
In Scope: Chocolate Chip Cookies in all NW Bakeries
Out of Scope: Packaging

Team: B. Thornton (BB), A Yamoto (Process Owner), W. Houston


(SME), P. Smith (SME), G. Hines (SME), L. David (SME)

Champion: T. Wong

Objective Statement
Reduce the scrap rate due to cracks from 15% to 8% by
11/12/07 as measured by the daily scrap report

BMGI. Except as may be expressly authorized by a written license agreement signed by BMGI, no portion may be altered, rewritten, edited, modified or used to create any derivative works.

Project Charter
Title: x

BB/GB: x

Business Gap

Financial Impact

$x

Milestones/Timeline:

Customer
External: x
Internal: x
Defects & Metrics
Defects: x
Primary: x
Secondary: x
Consequential: x

Problem Statement
x

Objective Statement
x

Define Tollgate Review:


Measure Tollgate Review:
Analyze Tollgate Review:
Improve Tollgate Review:
Control Tollgate Review:

Scheduled
x
x
x
x
x

Project Scope/Boundaries:
Process Start: x
Process Stop: x
In Scope: x
Out of Scope: x

Team: x
Champion: x

Actual
x

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