1. RIT SENIOR DESIGN PROJECT – P10711 WEGMAN’S MEAT TUMBLER PROCESS IMPROVEMENT Eric Albanese – Project Manager, Industrial Engineer Theresa Ambrose – Mechanical Engineer Okechikere Ekeada – Industrial Engineer Jeremy Gray – Industrial Engineer Jesse Wykstra – Mechanical Engineer

2.  The aim of this project is to improve the meat marinade tumbler transport in the Wegman’s Culinary Innovation Center. Our primary goals were to:  Fix ergonomic issues  Address safety concerns  Reorganize layout  Reduce waste 2

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4. Customer Requirements What we're measuring Customer Importance Current Values Marginal Values Ideal Values Solved by Proposal # ErgonomicsPrimary Risk Risk Rating Current Risk Rating Target Risk Rating Ideal Less back pain when loading multivac Dumptable9Very High722413 Less shoulder, wrist, and elbow pain when loading multivac Dumptable9Very High722413 Easier to grab meat when table almost empty Dumptable9Very High722413 Less shoulder and wrist/elbow pain when scooping bulk foods Dumptable6Very High722413 Less back/shoulder pain when pushing tables Dumptable9High362413 Better/less stressful cleaning methods for carts Dumptable9Very High82413 Easier to maneuver Column Dumper/ One worker to secure VEMAG Vat Column Dumper 9Very High262414 Easier to push vemag vatsVemag9High32415 Easier method to load carts into elevator Vemag3Low32415 SimplificationSpace Used Space Used Target Space Used Ideal More room to push carts around Space taken by carts/vats 3301 ft^215001 Better place to put used carts Space taken by carts/vats 3301 ft^215001 Better utilization of conveyor space Space taken by conveyor 3546 ft^227302

5. Goals Reduce # of VEMAG vat usage on the floor. Reduce dumptable inventory in front of Multivac station. Problems addressed Excessive # of VEMAG vats Too much full dumptable inventory  Used lean implementation tool, Kaizen to identify and eliminate waste.  Used process signals to establish a pull system.

6.  Reduced amount of space taken up by vemag vats  From 85 ft 2 to 56 ft 2  Reduced amount of space taken up by dump tables.  From 190 ft 2 to 82 ft 2  Established a pull system by implementing process limits between stations, reducing inventory.

7.  Goal of the project is reduce the space taken up the meat flattening progress 7  With the possibility of other tumbler process being moved into this room (estimated at least additional 32 sqft), better space utilization is a necessity Wegman’s had smaller conveyor in Brockport, NY facility that was transported to the CIC New conveyor is 18’ long, old one was 26’ long Worked to optimize the space use of the new machine Reworked layout to minimize amount of ‘dead space’. Completed ergonomic study to ensure safety

8.  Process converted successfully to smaller sized conveyor  Space taken reduced  Production capacity determined to 8 Customer Requirements What we're measuring Previous ValueMarginal ValueIdeal Values Actual Value SimplificationSpace Used Space Used Target Space Used Ideal Better utilization of conveyor space Space taken by conveyor 546 ft^2273 ft^20 ft^2270 ft^2

9. 9 Project Goals: Reduce the amount of bending/twisting required to unload the dump table at the multivac station. Improve the overall maneuverability of the dump tables. Simplify the dump table cleaning process. Results:  A spring loaded UHMW plastic insert greatly reduced the amount of bending/twisting that the employees have to perform while unloading the dump table at the multivac station.  The maneuverability of the dump table will be improved by adding a new caster design.  The cleaning process will be improved by adding a removable drain bucket.

10. 10 ItemDescriptionPrice 1.115” Stainless Compression Spring $299 2.120” Stainless Compression Spring $299 30.75” OD Stainless Tubing $107 41.25” OD Stainless Tubing $372 50.25” OD Stainless Rod $0.80 6Stainless Sheet Metal$29 7Perforated Stainless Sheet Metal $60 81” OD Stainless Ball$61 96” OD Stainless Swivel Casters $480 Total Cost: ~$1,708

11. 11  The spring-loaded grate mechanism was completed in the RIT machine shop.  The removable drain bucket will have to be completed by Wegmans.  The new casters will also have to be installed by Wegmans.  All of the new dump table features will have to be tested.  These new features will improve the ergonomics involved with unloading, transporting, and cleaning the dump table.

12.  Goals  Make column dumper require less force to move  Reduce the number of workers required to load column dumper with VEMAG Vat and secure it  Problems addressed  Ergonomic concerns workers have (complaints of a stressed and strained body after a busy day)  Reduce waste involved with using two workers to properly secure VEMAG Vats

13. Secondary Securing Mechanism:  Upside – out of the way  Downside – install on every vat  Carabiner  Test the purchased casters  Force Gauge  Worker survey  Purchase suggested casters  Modify Column Dumper for 6” casters

14.  3 Injuries:  Shoulder pain while working in the tumbling area  “A shooting pain” in hamstring from pushing a small empty vat out of the way  While pushing a full vat into the power lifter, shooting pain in shoulder  Loading into dumper:  Very large push required for vat to “click” securely in place

16.  Vat handle was constructed and attached successfully  Used round stainless steel tubing for easier bending and welding  1/8” thick, 1” OD, same lengths  Ergonomic risk rating was reduced from 3 to 1  Still not a large risk, but the injuries related to bending are going to practically disappear  Initial feedback from team members and machine shop staff is very positive  Waiting on feedback from floor employees

17. Customer Requirements What we're measuring Current Values Marginal Values Actual Values Met Goals ErgonomicsPrimary Risk Risk Rating Current Risk Rating Target Risk Rating Actual Yes/No Less back pain when loading multivac DumptableVery High72241 Expected Less shoulder, wrist, and elbow pain when loading multivac DumptableVery High72241 Expected Easier to grab meat when table almost empty DumptableVery High72241 Expected Less shoulder and wrist/elbow pain when scooping bulk foods DumptableVery High72241 Expected Less back/shoulder pain when pushing tables DumptableHigh36241 Expected Better/less stressful cleaning methods for carts DumptableVery High8241Expected Easier to maneuver Column Dumper/ One worker to secure VEMAG Vat Column Dumper Very High2624N/ANO Easier to push vemag vatsVemagHigh3241Yes Easier method to load carts into elevator VemagLow3241Yes SimplificationSpace Used Space Used Target Space Used Ideal More room to push carts around Space taken by carts/vats 301 ft^21500Yes Better place to put used carts Space taken by carts/vats 301 ft^21500Yes Better utilization of conveyor space Space taken by conveyor 546 ft^2273270Yes

18. SUCCESSES:ISSUES:  Issues with parts tracking and ordering  Discovered some overlap with existing Wegmans projects and had to modify plans  Could have used more test time with prototypes  Email communication could be better  Miscommunications between involved parties  Process inventory controlled and reduced  Opportunities for other process additions to marinade room  Discovered and reinforced existing issues  Carried designs from concept to completion  Created working prototypes for mass production  Got experience working as consultants in a multidisciplinary team

19. Suggestions for Future MSD Projects:  Collaborate with other MSD groups for parts ordering/receiving  Have large formal introduction meeting at start where we meet everyone involved (management, parts ordering, operations, etc)  Less time should be spent on deliverables in MSD1 and more time spent on ordering, building, testing in MSD2  Keep standing meeting every week and cancel as needed