MSD Parbake Mezzanine Final Meeting Clem Pin (ME) Sam Phillips (ME) Graham Frasch (ME)Simon Stam (ME) Matt Lynch (EE) Stefan Colegrove(EE)

Agenda Design overview Testing review Customer needs Space constraints Optimal bread sorting Next steps

Project Task To reduce the ergonomic risks associated with bread packaging in the Parbake Mezzanine ◦ Scope limited to Mezzanine room.

The Design

Testing Testing DaysTesting Hours 10/18/ /30/ /3/ /4/ /11/ /13/ /15/ /20/ /27/ /29/ /31/ /5/ /12/ /16/ Total Days: 12 Total Hours: 37 Man Hours: 185

Pane Italian

Rounds

Testing Summary ProductGuidesCounterSorter Percentage RollsMediumVery GoodGood 12.4% RoundsVery Good Good 23.5% LoafMediumVery GoodGood 49.8% BaguettesPoorVery GoodGood 14.3%

Customer Needs Customer Need # ImportanceDescriptionProgress as of 2/24/12 CN1High Reduces Ergonomic Risk Yes CN2High Fills Boxes Correctly * CN3Med Is Durable Yes CN4Med Can be Cleaned/Sterilized Yes CN5High Can Maintain Production Rate * CN6Med Can be Easily Repaired Yes CN7High Meets Food Safety Requirements Yes CN8High Handles 80% of Products * CN9Med Meets Budget/ROI * CN10High Safely Fits in Allotted Area Yes CN11High Is Reliable *

*Comments CN2 – Counter and Lane Sorter work ◦ Awaiting system integration CN5 – Not all products tested ◦ Rounds Yes ◦ Pane Italian dependant on upstream orientation CN8 – 69% Tested CN11 – Most recent testing required operator intervention once every 10 minutes

Space Constraints Bread Sorting ◦ Current approach requires more conveyor area Box Coaster ◦ Requires more space between top conveyor and bread loading area Room Layout ◦ Current empty box stacking conflicts with required space

Conditions for Optimal Bread Sorting General Product Flow  Observed to be 60/40 with right side bias  50/50 is ideal  Conveyor speed increase  Decreases instantaneous product density at guides Pane Italian  Reorientation after oven exit  Single file orientation as proposed by 5-second delay

5 Second Delay

Lessons Learned Sorting bread is a complex process Fabrication Reworks ◦ CAD drawings provided were ambiguous.  Sit down meeting might have been required Upstream Sorting ◦ Made late push which showed promise ◦ Initial focus limited to the mezzanine

Next Steps Investigate upstream orienting solutions Commit to conveyor speed increase ◦ Purchase different gear drive Bring conveyance vendor in house for assessment on box conveyor

Wegmans Recommendations Provide onsite storage for testing components Provide access to a small basic tool set ◦ Much time was spent looking for tools to use

Questions?