Marble Cake Process Improvement – Final Review Aaron Delahanty Arwen Sharp Benson Yu Kenyon Zitzka Ryan Norris

Presentation Outline Mentality – As a team we have invested a lot into this project and have unavoidably become attached. Despite this, the goal for this final review is to asses our progress up to present, our current project state, and future work in an honest and clear way that provides the most value to our customer. Project Re-scope –Schedule –Customer Needs Current Status –Near future test plans Known Issues Deliverables Project Insights Acknowledgements

Project Re-scope Due mainly to a quickly approaching deadline, fabrication, assembly and testing of the system components critical for task completion have been major focus of the second quarter. Fabrication, assembly, and testing of the following system components has been halted: Cart Shielding Gate Mechanism Team resources have been allocated to: Assembly / calibration of Machine Head Development of test process (product line mock-up) PLC / Controls integration

Project Re-scope – Further Justification Option 1 Force the delivery of a under tested, unproven system Option 2 Deliver well developed machine ‘head’ prototype Spend more resources further investigating primary mechanisms Better develop PLC logic More time testing and revising Provide Wegmans with more thorough documentation (including complete system design)

Current Project Status Completion of Motor Module Motor Gear Train Quick Disconnect Swirlers Complete Assembly of Machine Head/Chassis Pneumatic Actuation Sensor Integration Initial PLC programming complete Sensor / PLC integration Development of a test stand Simulation of product line environment

Initial Motor Module Testing (out of chassis) Swirl performance: Initial Swirlers provide satisfactory results Further refinement of design could significantly improve swirl aesthetics

Near future Test Plans Prototype capability: Full mock-up of bakery conveyor line, designed to test and debug PLC integration Complete sheet pan batter testing Quality Repeatability Process Cycle Time Batter Drip Fatigue / Endurance Testing

Known Issues Vertical Translation – Pneumatics / Guide Rails Design: Root Cause – Design requires unrealistic precision given available resources Warping of box frames Low angular misalignment allowance Even if consistently smooth translation achieved, must be secured as well Potential Solution: Alternative linear bearings Neutrally load the middle frame (Solutions 1 & 2, low cost, easily implemented) Stronger box frame High precision machining Investigation of alternative lift / alignment mechanisms Signal communication between sensors, actuators, PLC Root Cause – Poor schematic documentation Temporary Test Set-up Potential Solution: 1. Complete electrical schematic 2. Cleaner wire routing

Known Issues Inadequate Aesthetic Swirler Performance (unconfirmed): Root Cause – Untested final swirler prototype Variability due to manufacturing Potential Solution: Further testing Swirler redesign and remanufacture (Relatively low cost, easily implemented) Further Pan Alignment Calibration Root Cause – Edge tolerances (Both inductance sensor and Swirler Maximum Radius Condition) Potential Solution: 1.Development of auxiliary guide mechanism 2. Loosen Edge Tolerances (Sacrifice swirl area)

Summary of Deliverables Complete functioning prototype PLC Logic Wiring Schematics Complete CAD library –Drawings –3D models –Hierarchy BOMs Explanation of current design choices and recommendations for future work

General Insights / Recommendations for future work Early communication with machinists Lack of PLC / ladder logic from either ME or EE RIT curriculum Make availability of resources known PLC programming Wegmans recommended parts and specs Manufacturability of Design

Acknowledgments Professor John Kaemmerlen Mike Least Gary Kittrell Rick Norder Tony Contrera and Dean Wight Professor Scott Bellinger and his class

And thank you to Wegmans for the opportunity.