The document discusses observations and recommendations for Veggie Patch's meat substitute packaging process. It notes that Veggie Patch has the third largest market share in meat replacements and distributes through retailers and clubs. The analysis team observed the final packaging line and identified two product sizes. Recommendations include converting the line from an L-shape to a U-shape to reduce idle time, reconfiguring the conveyor system to prevent jams, and adding more visual signals to alert workers to issues. After analysis, the team learned that minor misalignments can reduce efficiency and setup/changeover times are a major source of lost time.

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