1. Systems Level Design Review Project #10715 1/15/09 Rev 011

2.  Helen Jervey (ISE), Project Lead  Charles Nicolosi (ME), Chief Engineer  Brandon Sbordone (ME)  George Kilger (EE)  Ian Baker (ME)  Ben Bouffard (EE)  Advised by John Kaemmerlen Rev 012

3.  Provide background information about the current system at the Culinary Innovation Center  Detail the progress made by the team from RIT  Receive feedback from faculty and Wegmans staff  Discuss the next steps in the process Rev 013

4. Customer Needs Engineering Specs Rev 014

5.  Wegmans is a food market with more than 70 stores in five states  The Culinary Innovation Center, or CIC, provides all premade sauces and marinated meat products to Wegmans stores Rev 015

6.  The current factory line requires seven people performing repetitive, injury prone tasks  Injuries have cost Wegmans more than $20,000 in the marinade area since the opening of the CIC  Unreliable labeling technology leads to rework, wasting the time of the employees Rev 016

7.  Reallocate direct labor from flipping, labeling ◦ Allow employees to move to other areas of the CIC  Reduce ergonomic risks on line  Perform all work within safety and quality  standards Rev 017

8.  Primary ◦ Meet AMA, OSHA, USDA and other relevant standards ◦ Maintain integrity of product  Secondary ◦ Reallocate direct labor from flipping, aligning ◦ Automate or improve flipping, aligning, and labeling processes ◦ Maintain or improve takt time Rev 018

9. ◦ Need 1: Product & Process are Safe  Need 1.1: Product integrity is maintained  Need 1.2: Equipment satisfies USDA Regulations as well as the AMI Checklist  Need 1.3: OSHA Safety requirements are met  Need 1.3A: Remove ergonomic issues and concerns ◦ Need 2: Reallocate Direct Labor  Need 2.1: Reallocate direct flipping labor  Need 2.2: Reallocate direct alignment labor  Need 2.3: Reallocate direct labeling labor Rev 019

10. ◦ Need 3: Improve Processing Time  Need 3.1: Maintain or decrease takt time  Need 3.2: All packages get scanned by the x-ray at desired belt speed  Need 3.3: Control flow to scaling operation. (Control flow- rate variance)  Need 3.3A: Meet x-ray specs of one piece at a time in machine ◦ Need 4: Control orientation and flow-mechanics  Need 4.1: Packages are in the proper orientation  Need 4.1A: Label is in proper orientation position relative to the package  Need 4.1B: All packages are centered in the x-ray beam  Need 4.1C: Packages are conveyed in single-file o Need 4.2: Avoid impact on other projects  Need 4.2A: Keep allocation of floor space constant Rev 0110

11. and Feasibility Analysis Rev 0111

12.  Constraints ◦ Space ◦ Feasibility ◦ Alignment ◦ Efficiency ◦ Mechanical/“Intelligent” AlignFlip X- Ray Label Rev 0112

13. System Concept Selection Rev 0113

14.  Mechanical Process  Allows for basic single file flow  Engineered for product inconsistencies  Will need future testing for jam concerns  Basic frictional analysis shows it is feasible Concept Improvement (Though Testing) Rollers Belts Actuated Rev 0114

15. Frictional Feasibility Analysis Rev 0115

16.  Mechanical process  Reliably performs a uniform flip  Handles different package sizes and configurations  Handles constant stresses of use  Need component life cycle analysis Concept Improvement (Through Testing) Adjustable Tray Motor Choice Tray Angle Rev 0116

17.  Must consistently apply identifyer label  Controlled label orientation and position  Imaging/sensing system  Implementation and modification of current labelers to fit project  Research has found feasible camera systems in industry Concept Improvement Professor Meetings Camera Selection Rev 0117

18. Rev 0118

19. Align Align product mechanically Guide rails or rollers Push products to center of conveyor Flip Flip product mechanically Offset belt system (upper and lower) Flipper arm or tray One piece at a time X-Ray Automatic accept/reject Label Add identifier label Fully/partially automated or manual Ability to reorient based on product angle and displacement offsets Rev 0119

20. Pieces enter in 2 or 3 wide Adjustable, offset guides Actuated guides to align pieces/accelerate alignment process Proximity/contact sensors to ensure guide return Laser sensor for piece(s) entering guide path Guide actuates and pushes pieces to center Pieces align with belt friction Rev 0120

21.  Fixed/Adjustable Guides ◦ Solid rail ◦ Roller guide ◦ Belt guide  Powered/Adjustable Guides ◦ Solid rail/roller guide ◦ Hinge mount for guide ◦ Actuator/Actuators ◦ Proximity sensors ◦ Laser sensors for track Rev 0121

22. Piece flows into flip tray Laser sensor indicates piece in tray Stop arm for next piece Motor/actuat or rotates flip tray Piece is pushed out of tray Sensor indicates no piece in tray Motor/actuator rotates flip tray Stop arm retracts Automated Flipper Rev 0122

23.  Flipper Tray ◦ Grated ◦ Solid  Stop Arm ◦ Actuator ◦ Hinge ◦ Proximity Sensor(s)  Flipper ◦ Motor/Actuator ◦ Mounting/Hinges ◦ Piece sensor (laser) ◦ Proximity sensors (up/down) ◦ Product pusher  Fixed  Mechanical  Proximity sensor  Actuator Rev 0123

24. Single piece enters Vision system identifies package System outputs θ and offset (x,y) Motors align label head based on output Laser sensor (possibly stops belt and) activates vision system Label application Label head retracts/ Returns to home (Belt resumes) Identifier Label Applicator Rev 0124

25.  Vision System ◦ Laser product sensor ◦ Visual comparator system  Camera  Comparison logic controller  Label Applicator system ◦ X-axis motor ◦ Y-axis motor ◦ θ motor ◦ Label applicator head  Head actuator  Labeler  Foam presser ◦ Label loader  Belt motion controller Rev 0125

26. Pieces From Multivac Trip Laser sensor(s) Guide Returns Piece leaves beam Single file flow to flip Piece enters flip tray Piece prox. sensor trigger Stop arm actuates Tray actuator trigger Tray rotates down Trigger push prox. Piece prox. Trigger off Tray rotates up Stop arm retracts Piece to lower conveyer Piece through x-ray Piece trips laser Belt stops Camera shoots image Calculate s θ, x, y Labeler assembly offsets x Labeler assembly offsets y Labeler assembly offsets θ Remove label from spool Label head actuates down Label head retracts Belt resumes Guide actuator(s) activate Rev 0126

27. Rev 0127

28. IDRisk ItemEffectCause Likelihood Severity Importance Action to Minimize RiskOwner 1 Upstream process changes downstream variables Engineering specs become obsolete, device may no longer meet customer requirements P10711122 Project managers meet to discuss changes several times during quarter (week 4, rest TBD) PM 2 Device requires many on- floor adjustments Deliverables not met, client may discontinue use of device Wide package spec range, overly specialized device 224 Device will be set to one, “best” setting; if not possible team will devise as few as possible device settings and develop easy-to-use documentation ME, ISE 3 Modified work tasks are ergonomically risky Workers are injured, slowed production Frequent, repetitive tasks; lifting; flipping 224 Proposed tasks evaluated using ergo risk assessment tool; tasks modified to be less than 24 on scale Helen 4 Device does not meet cleanliness standards Device cannot be used by client Inappropriate materials used, incompatible with cleaning methods 236 AMI Sanitary Design Checklist used to drive all applicable design decisions; device designed to work with current sanitizing methods Helen 5 Device does not work with lightest or heaviest packages Device cannot be used by client Weak design, inappropriate materials 339 Packages beyond dimensions of product range will be tested (TBD) ME 6Device cannot perform at current takt (6 sec) Device cannot be used by client Weak design, mechanical limitations 236Device will be tested at quicker takt (TBD) All Rev 0128

29. IDRisk ItemEffectCause Likelihood Severity Importance Action to Minimize RiskOwner 7 Device damages or compromises packages Device cannot be used by client Excessive speed/force; sharp edges; pinch points 236 Device tested at range of speeds and forces; test package puncture force? All 8Labeler jams frequently Slowed production, rework Inadequate hardware 236 Sensing system tested at wider range of speeds and package sizes than expected EE 9 Labeler applies misaligned labels frequently Added visual inspection, rework Weak design; inadequate hardware 224 Sensing system tested at wider range of speeds and package sizes than expected EE 10 Flipping task frequently misaligns package Slowed production, direct manual labor, x- ray misses parts of package Weak design; inadequate hardware 224 Sensing system tested at wider range of speeds and package sizes than expected Brandon 11Flipper jams frequently Slowed production, direct manual labor Weak design; inadequate hardware 236 Sensing system tested at wider range of speeds and package sizes than expected Brandon 12 Aligner frequently places packages outside x-ray beam Slowed production, direct manual labor, x- ray misses parts of package Weak design; inadequate hardware 224 Sensing system tested at wider range of speeds and package sizes than expected Charlie 13Aligner jams frequentlySlowed production, direct manual labor Weak design; inadequate hardware 326Sensing system tested at wider range of speeds and package sizes than expected Charlie Rev 0129

30. IDRisk ItemEffectCause Likelihood Severity Importance Action to Minimize RiskOwner 1 Team member has extended absence Critical chain affected Illness, personal issues 313 Thorough documentation during absence to reduce “catch up” time; team will communicate as much as reasonable during absence All 2Resource over-allocated Deliverables delayed or contain errors Improper resource allocation, over- volunteering 313 PM will check in with all team members weekly to ensure workload is balanced PM 3Parts delayed from supplier Critical chain affected, deliverables delayed Special parts, clerical errors, parts lost 224 Use approved vendors, have multiple vendors, use off-the-shelf parts PM 4Customer priorities change Customer needs, specs become obsolete Business environment change 133 Constant communication with customers regarding needs All 5Insufficient risk assessment Slow response to problems, critical chain affected, deliverables delayed Insufficient thought process 224 Constantly reexamine project and technical risks to ascertain changes All 6Team member leaves MSD Critical chain affected, deliverables delayed Illness, personal issues 133 None. Keep in communication with all team members to plan for reallocation ASAP PM 7 End users unhappy with device Customer needs not met, device cannot be used by client User input not considered during design, design not suited to users 339 Include end user input in all phases of design; practice active listening; ask “Why?” when concerns are raised to find root cause All 8Budget changes during project Engineering specs may be infeasible, customer needs change Business environment change 133Adjust project goals, demonstrate cost savings of project and return on investment PM Rev 0130

31. Rev 0131

32.  Evaluate analyzing methods for the labeling device  Gather data on packaging durability  Research optimal methods of flipping and aligning  Draft circuit designs for controls and sensors  Draft schematics for mechanical devices  Investigate costs of long lead time devices  Physically implement designs  Test "first run" designs on product  Revise and improve designs  Detailed Design Review: Friday 2/12 (4 weeks) 32Rev 01

33. 33Rev 01