Wegmans Swirl Cake Process Improvement Multidisciplinary Senior Design RIT Fall / Winter 12712

Project Preamble As the current swirling process is done manually… The ultimate goal of this project is to possibly improve Wegmans' marble cake swirling process with a full automation in order to… 1.reduce production costs, 2.improve the ergonomics of production line, 3.offer a long and consistent service life

Outline – System Design Review Team Members Project Requirements & Goals Project Planning Concept Generation & Selection System Requirements Overview & Sample Products

Team Members Ryan Norris (Team Project Manager) (ME) Aaron Delahanty (ME) Arwen Sharp (EE) Benson Yu (EE) Kenyon Zitzka (ME)

Project Requirements & Goals Project Requirement (Customer Needs) – see attachment no.1 Customer Need # DescriptionComments/Status CN1 Change over time; 15 minutes or not interfere with operations CN2Swirl 6.69 sheets per minuteOur swirling process cannot act as product line bottleneck CN3Stay under $2500 for project CN4Machine needs to withstand sanitizing/cleaningMaterial choice based on solvents used CN5Machine must be food safeFood safe material/lubrication also See CN19 CN6Machine should have future capability for circular pansCustomer must specify if this is priority CN7Limit excess batter drip onto conveyorAddressed by design CN8Use 120 v, 240 v or 440 v power CN9 Easy to maintain, service and obtain parts (limit downtime) Use current suppliers, overall simple machine design CN10Maintenance and service documentation provided. CN11Moving parts must be contained to avoid injury Addressed by design, use of warning labels, and standard safety guards CN12Chocolate batter must be swirled to aesthetic completionRequire expert opinion from artisan (surface vs cross section) CN13 Machine needs to be capable of switching between 1/4 and 1/2 pans Addressed by design (Ideally no machine alteration req'd between 1/4s and 1/2s) CN14Low energy consumptionLow risk CN15Limit noiseLow risk CN16Limit machine sizeMore data needed CN17Limit use of small hazard partsAddressed by design CN18Limit machine weightMore data needed

Project Requirements (2) Engr. Spec. # Source Specification (description) Unit of Measure Ideal Value Marginal Value ES1CN1Changeover timemins7<15 ES2CN2Allotted sheet swirl time (to prevent oven starve)sec/sheet4 <8 ES3CN3CostUSD1500 <2500 ES4CN15Noise limitdB quiet as a mouse80 ES5CN13Unswirled gapin ES6CN16Machine Footprintft^2 ES7CN18Machine Weightlb Project Specifications – see attachment no.2

Project Planning (1) Timeline – see attachment no.3

Project Planning (2) Risk Assessment – see attachment no.4 1.Food Sanitation – see no.7 2.General Safety Concerns – no.9 3.Durability Expectation – no.26 4.Ability to Swirl ½ and ¼ pans – no Long Lead Time on Parts – no. 4

Concept Generation Functional Flowchart

Concept Generation (2)

Concept Selection

Concept Selection (2) Overall System Architecture

Concept Selection Process Hands on Brainstorming Refined Swirling Techniques Full scale Mock-up Performance Analysis

Concept Selection (3) Pugh for Swirling. Swirl Device Concepts Rotating swirlers (9,6,4,2) Rotating chassis + rotating swirlers Rotating Chassis + rotating swirlers + translation Rotating swirlers + translation DATUM - Path CriteriaSpeed of swirl '+'---S Cost '+ S System Complexity '- S Flexibility '- S - 1/4 1/2 gap * '- S Legend:- circular pan * '- S + = better than current process - resource availability '+ S S = equal to current process Mess/ Drip '+ S - = worse than current process Aesthetic performance SSSSS Consistancy '+ S Safety '+ S -ergonomics '+ S

Swirling Mock-up Pictures of progress

Swirling Mock-up (2) Swirling Analysis Tools Used: Kinex and electrical drill

Swirling Mock-up (3) Tools Used: Modified Whisk

Mock-up Results

Mock-up Results (2)

Mock-up Results (3) After 7 minutes in oven..

Performance Analysis Swirl Device Concepts Rotating swirlers (9,6,4,2) Rotating chassis + rotating swirlers Rotating Chassis + rotating swirlers + translation Rotating swirlers + translation Speed of swirl1233 Cost1233 System Simplicity1233 Criteria Flexibility - 1/4 1/2 gap * circular pan *323 - resource availability1111 Mess/ Drip1122 Aesthetic performance2321 Potential Performance Comparison Legend: 1- Good 2 – Satisfactory 3 - Poor

What’s Next? Detailed Design Work  Mechanical and Electrical Sub-assemblies Design Review (November 4th) Finalize BOM and Submit parts order

Questions for Moving Ahead Our immediate concerns:  Understanding needs for swirl aesthetic What defines a complete swirl? Surface swirl vs. Cross-sectional swirl  Opinions/Concerns for mobility What sanitation standards are there? What spatial concerns exist?  1/4 pan to 1/2 pan gap Swirl quality vs. Production flow