General Mills
General Description
- General Mills plant in Joplin. MO is a major manufacturer of frozen bread products that are shipped globally.
- General Mills was experiencing a 10-12% labor defect based on their daily production schedule.
- TPT’s focus was on three (3) primary production lines.
Scope
- Conduct detailed (current state) MODAPTS time studies on all three production lines. Our focus was on direct and indirect labor supporting daily production.
- TPT identified all non-value-added activities on all three production lines.
- Quick hit rapid improvement initiatives were implemented to further reduce waste and inefficiencies. TPT’s Industrial Engineers conducted daily meetings with General Mills stakeholders to implement lean and efficient work cells which was driven by MODAPTS data.
- Certain work elements and inefficiencies were balanced out of the production process.
- Developed new operator work instructions and training to the production operators.
Success
- With the waste identification and rebalancing both direct and indirect work elements and instructions. General Mills was able to level set the three production lines and eliminate stress on the operators. No additional operators were required to meet their daily production targets.
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