Current PAT Projects Change Overs (85%

complete)• Joel Bugbee/Kurt Geiger

Process Sanitation• Nick

Master cleaning training• Cesar Pajuelo

FMS Mercotac• Duane

Material Variance• Barbara valentine (Oil)

Broken Film• David Blackner

Office 5-S• Dave Samuelson

Standardization of Line 3 set up• Dean and Cesar

Lot code rework• Production, Warehouse,

and QA

Vibratory Waste Tracking

Aug Sept Oct Nov Dec Jan Feb March April

S1

$6,285.06

$2,763.49 $2,867.52

$697.31$979.53$932.00$1,482.17

$2,039.40

$888.89$-

$1,000.00

$2,000.00

$3,000.00

$4,000.00

$5,000.00

$6,000.00

$7,000.00

Vibratory improvement waste in dollars line 2

Identify Safety Hazard PATProcess Action Team

Team Owner: John King Team Name: Identify Safety Hazards

Team Members Current Process Proposed Process

1 John King 1 See attachments 1 See attachments 2 Duane Gagnon 2 23 Ronnel Porter 3 34 4 45 5 56 6 67 7 78 8 89 9 9

10 10 10

Metrics Identified to Measure Effectiveness Goals

1 Total incident rate for plant 1 Identify safety hazards2 Before & After pics to identify change 2 Fix safety hazards3 34 45 5

Current Projects (all previous projects complete)

Elevator gate to be welded• Complete

Mixer gates did not lockout when opened• Complete

Pump for BBQ sauce needs to be automatic so operator doesn’t need to run around machine to pump sauce• Complete

Safety door switch on compactor needs rewiring• Completed by Waste Management

FMS WrapperPAT

Presented byDuane Gagnon

Members Involved

Anita Trujillo Amado Jimenez/Andrea Begay Chris, Boni, Monte Kelso. Frank Brown, Duane G Cesar Pajuelo John King.

FMS WRAPPER PAT MINUTE

Today 5/10/07 was the start of the FMS wrapper PAT. Its mission is to come up with a solution in how not to get the Mercotec wet which sits at the bottom of the Finseal. Sanitation: Will shut the power to the FMS wrapper and cover the finseal area and begin its full sanitation on the opposite side of the finseal (where the chain starts). Once the cleaning process is complete they are to air hose it, take the covers off and start the machine. Sanitation will also be on the look out for open junction box and immediately report them to maintenance so that the maintenance dept will begin to minimize electrical problems. Maintenance: has begun in making that area water friendly by making holes, they will keep track of the start ups. Duane and Frank will take pictures of what areas are critical and put a presentation together to be shown to sanitation. They will also be using Non conductive grease to help prevent from having water enter in electrical areas. Important both dept will work together through mutual open communication.

GOALS for FMS WRAPPER WATER PAT TEAM SANITATION TO DEVELOP NEW PROCEDURES FOR CLEANING WRAPPERS OBJECTIVES: CONTAIN WATER AND MAINTAIN CLEANING GOALS STARTED 5/3/07 SENT A WORK ORDER TO MAINTENANCE TO COME UP WITH A COVER FOR THE WRAPPERS for sanitation to use ON 5/16/07. MAINTENANCE: ORDER AND INSTALL NEW PLUGS FOR THE MERCOTAC'S PACK PLUG WITH DIELECTRIC COMPOUND OBJECTIVE: KEEP WATER OUT COMPLETED NORTH WRAPPER 5/21/07 SOUTH WRAPPER 5/28/07 MONITOR IMPROVEMENTS

Mercotec Chart

0 0 0

1 1 1 1 1 1

0

blew it blew it Floor mtgexperiment

Good Good Good Good Good Good merc was putbackward

30-Apr 5/1/2007 5/2/2007 5/3/2007 5/7/2007 5/10/2007 5/15/2007 5/16/07 5/18/2007 5/22/2007

0= blew it.1= Good

WRAPPER START UP CHECK LIST

1. Check all guards and make sure they are secure. 2. Turn air supply on. 3. Check lug chains for any damage or bent lugs. 4. Check rotary infeeds for any damage, loose parts and

check the timing. 5. Check the rotary infeed chutes for any missing parts. 6. Make sure all the clutches are locked in. 7. Check all safety switches for proper operation. 8. Check each fin seal & crimp head for proper temp

with the Omega temperature hand held or IR gun. 9. Zero the wrappers. 10. Make sure all rails are adjusted properly. 11. Start and run the wrappers to insure they will run

production. Then load film. 12. Check tracking on the out feed belt.

Date Signature.

Breaded Chik’n 520055

Dean, Cesar, Frank, Cory N.

Transfer Belt

• Transfer lining up to fryer. Notice the placement. This is standard with with 520055, 520136, and 520137.

CrumbMaster to Transfer

• Standard with 520055, 520136, and 520137 as far as height of belt. Should not be changed.

• Pin holes line up for exact height setup.

CrunbMaster to Transfer Belts

• Top view of pin placement and belt alignment.

• Outside edge of Crumbmaster belt lines with inside hooks of the Transfer belt.

Transfer to Fryer Belts

• Proper alignment of transfer will align the first linkage of the transfer with the inside edge of the fryer belt link.

Wet Coater

• The wet coater should be level when properly placed in line.

Wet Coater to CrumbMaster• Pin Hole has been

modified with an extension that is bolted on. This extension should not be removed.

• Wet Coater will pin in place when the wet coater hole aligns with the extension hole.

Do Not Remove

Wet Coater to CrumbMaster

• Side view of the extension and pin placement.

Former to Wet Coater• With the wet coater level

and pinned inplace, the former will lay on the front edge of the wet coater.

• NOTICE: The first linkage of the wet coater belt aligns in the center of the irst likage of the former belt.

Lot Code Wrong / Missing PAT

Prod, Warehouse, QA

• First meeting held Wednesday may 23rd to examine all issues that are causing the lot code to be missed on shippers.

• PAT members: Dean, Ron, QA Tech, Dayshift Warehouse, Swingshift Warehouse.

Issue’s / Data

6,606

4,163

2,548

8,543

$11,150

$7,027

$11,097

$16,886

$5,219

$3,289

$2,013

$6,749

0

2,000

4,000

6,000

8,000

10,000

12,000

14,000

16,000

18,000

Feb-07 Mar-07 Apr-07 May-07

PoundsStandard CostRework Cost

•Unplugged jetta mark at the Palletizer•Wrong lot code entered into the jetta mark at the Palletizer•Jetta mark at the Palletizer stopped working•Marsh printer quit working•Jetta mark at the Palletizer ran out of ink•Marsh printer ran out of ink•Marsh printer set up with incorrect dates

Actions

• First idea to solve unplugged Jetta Mark – to wrap the cords, similar to how a weed eater has a spot built in to the handle to wrap the extension cord through so the cord doesn’t pull out. This is the concept being looked at for this issue.

Up and Coming

• Destoner Cycle Time• Mixer Op recording cycle time• Plate/Give Away by SKU• Tiromat Film Material Variance

Old Standard vs. New Standard

020406080

100120140

Min

utes Old

New

GoalReduce 25%

Old Standard vs. Actual

050

100150

Min

utes

OldActual

Standard vs. Actual Individuals

010203040506070

Oven 2steam to

heat

Oven 1 LotCode

Change

FormerRinseDown

Changeover

Min

utes Standard

Actual

Bulgar Wheat Reduction P.A.T.

Presented by Stephanie Lobato

Slugformer Spill Points

Goal: Reduce Waste by 50%Status : Complete and Tracking

Monthly Waste Tracking

$9,072.00

$5,311.71$4,136.48

$3,050.77

$1,652.12$1,684.05

$1,952.88$1,308.10

$1,326.64$2,230.98

$-

$1,000.00

$2,000.00

$3,000.00

$4,000.00

$5,000.00

$6,000.00

$7,000.00

$8,000.00

$9,000.00

$10,000.00

Aug Sept Oct Nov Dec Jan Feb Mar Apr May

Slugformer and infeed Improvements