Project Review Presentation Project #10715 5/14/10 Flip Label Project Review Presentation Project #10715 5/14/10

Project Team Helen Jervey (ISE), Project Lead Charles Nicolosi (ME), Chief Engineer Ian Baker (ME) Ben Bouffard (EE) Brandon Sbordone (ME) George Kilger (EE) Advised by John Kaemmerlen (ISE) Rev 02

Project Review Agenda Project Overview & Goals Customer Needs & Project Specifications System Design Summary System Testing Plan Objective System Evaluation Project Budget & Justification Project Risk Assessment Future Project Progress Ideas for Future Work Rev 02

Project Overview & Goals Problem Statement The Flip-Label project goal is to reduce direct labor requirements for the flip/label meat package process sequence in the Wegmans Culinary Innovation Center. Currently an operator is needed to manually flip and align meat packages to enter the x-ray inspection machine. One or more operators are needed to label packages after they exit the inspection machine depending on product type and process speed. Objectives Implement devices to flip and arrange meat packages in optimal configuration on conveyor for inspection by x-ray scanner Reduce direct labor needed to label packages at current takt Rev 02

System Design Rev 02

Customer Needs Need The Product Needs to Imp. N 1.1 Product integrity is maintained Meet specifications 5 N 1.2 Equipment satisfies USDA Regulations as well as the AMI checklist N 1.3 OSHA Safety requirements are met 4 N 2.1 Reallocate direct flipping labor Decrease man-hours N 2.2 Reallocate direct alignment labor N 2.3 Reallocate direct labeling labor N 2.4 Camera labeling system is low priority Control project scope N 3.1 Maintain or decrease takt time Decrease processing time N 3.2 All packages get scanned by the x-ray at desired belt speed Scan all packages 3 N 4.2 Keep allocation of floor space constant Fit within specified area N 3.3 Control flow to scaling operation(Control flow-rate variance) Minimize variance N 4.1A Label is in proper orientation and position relative to the package Be aligned N 4.1B All packages are centered in the x-ray beam Scan entire package N 3.3A Packages must flow in a format that works with the X-ray Meet specification 2 N 4.1 Packages are in the proper orientation N 4.1Ba Packages are conveyed in single-file N 1.3A Remove ergonomic issues and concerns Minimize risks 1 Rev 02

Engineering Specifications Engr. Spec. # Imp. Need Met  Specification (description) Unit of Measure Marginal Value Ideal Value ES1 3 N 4, 13 Flow Rate pc/min 7 >7 ES2 2 N 9, 10, 12, 13, 14 Pc. Alignment in. from center +/- 1 in ES3 N 9, 12 Perpendicularity (deg) 90 +/- 10 90 +/- 3 ES4 Label Orientation ES5 5 N 1, 2 FDA/USDA Specs Pass/Fail pass ES6 N 1, 2, 15 AMI Safety Specs ES7 N 1, 3 OSHA Specs ES8 4 Flip Angle ES9 N 4, 8 Belt Speed (X-Ray) m/s or ft/s Current ES10 N 6, 7 Direct Flip/Align Man Hours hrs. <75% of current <50% Current ES11 N 5 Direct Label Man Hours ES12 N 1 Keep Product Integrity Yes/No Yes ES13 N 15 Ergonomic Risk CIC Risk Units <24 ES14 1 N 11, 14 Flow Rate Variance % of rate ⁻₊25%-50% 0%-25% ES15 N 16 Floor Space Allocation Sq. Ft. Current +/- 18 in Current +/- 6 in ES16 N 9 Label Position Coordinate (x,y) Center +/- 0.5 in +/- 0.25 in Rev 02

Systems Design Rev 02

System Design-Flip Rev 02

System Design-Flip Rev 02

System Design-Align Rev 02

System Design-Align Rev 02

System Design-Sensors 42CM LaserSight Photoelectric Beam Sensor Digital beam sensor Detects when a package breaks the projected beam 45BPD Laser Measurement Sensor Analog distance sensor Outputs a function-dependant voltage based on the distance between the sensor and the package Rev 02

System Design-Controls Micrologix 1100 Receives all data from sensors Outputs control signals to motors PanelView Plus Compact Panel Touch screen interface Allows quick, easy control of line PowerFlex 4 AC Drive Controls the belts Requires no input Rev 02

System Design-Labeler Cal-Pak Automated labeling system researched and a design was agreed upon Implementation delayed until all other subsystems completed Label Assist Short-term solution Increases labeling speed while decreasing ergonomic stress Rev 02

Results Rev 02

Test Plan Example Rev 02

Objective System Evaluation Engr. Spec. # Imp. Need Met  Specification (description) Unit of Measure Marginal Value Ideal Value Status ES1 3 N 4, 13 Flow Rate pc/min 7 >7 ES2 2 N 9, 10, 12, 13, 14 Pc. Alignment in. from center +/- 1 in ES3 N 9, 12 Perpendicularity (deg) 90 +/- 10 90 +/- 3 ES4 Label Orientation ES5 5 N 1, 2 FDA/USDA Specs Pass/Fail pass PASS ES6 N 1, 2, 15 AMI Safety Specs ES7 N 1, 3 OSHA Specs ES8 4 Flip Angle ES9 N 4, 8 Belt Speed (X-Ray) m/s or ft/s Current CURRENT ES10 N 6, 7 Direct Flip/Align Man Hours hrs. <75% of current <50% Current ES11 N 5 Direct Label Man Hours ES12 N 1 Keep Product Integrity Yes/No Yes ES13 N 15 Ergonomic Risk CIC Risk Units <24 ES14 1 N 11, 14 Flow Rate Variance % of rate ⁻₊25%-50% 0%-25% ES15 N 16 Floor Space Allocation Sq. Ft. Current +/- 18 in Current +/- 6 in + 18” ES16 N 9 Label Position Coordinate (x,y) Center +/- 0.5 in +/- 0.25 in Key Pass Fail In Progress Not Yet Tested Rev 02

Project Budget & Justification System Summary Subsystem Parts Total Labor Est Subsystem Total Flipper $2,736 $1,040 $3,776 Flipper Controls $5,131 $0 Aligner $4,657 $1,280 $5,937 Aligner Controls $2,618 Conveyors $13,482 System Total $30,944 Helen add more Rev 02

Project Risk Assessment ID Risk Item Effect Cause Proposed Actual Action to Minimize Risk Owner Likelihood Severity Importance 2 Team member has extended absence Critical chain affected Illness, personal issues 9 1 Thorough documentation during absence to reduce “catch up” time; team will communicate as much as reasonable during absence All Illness Team used email and other forms of communication. Documentation was completed and distributed. 4 Parts delayed from supplier Critical chain affected, deliverables delayed Special parts, clerical errors, parts lost 3 27 81 Use approved vendors, have multiple vendors, use off-the-shelf parts PM Critical chain affected, infeasible to complete deliverables Clerical errors(?), parts lost(?), ??? Contacted vendors, escalated problems. 6 Insufficient risk assessment Slow response to problems, critical chain affected, deliverables delayed Insufficient thought process Constantly reexamine project and technical risks to ascertain changes Ordering mishaps adsf Insufficient risk assessment covers other issues in part procurement E.g.: delayed engineering drawings from Lipe delayed critical chain tasks Rev 02

Future Project Progress Continue system manufacturing and assembly Test individual subsystems Integrate subsystems Test complete system Debug and refine process Secondary line replication Rev 02

Ideas for Future Work Ergonomics Develop secondary standardized system for assessing risk for hand motions/non-lifting tasks Paper recommended by Dr. Matt Marshall (ISE) 2/8/10 “Development and evaluation of an observational method for assessing repetition in hand tasks”. Wendi A Latko; Thomas J Armstrong; James A Foulke; Gary D Herrin; et al. American Industrial Hygiene Association Journal; Apr 1997; 58, 4; ABI/INFORM Global. pg. 278 Marinated Meats Line Simulation Project Discrete event simulation of entire marinated meats line Possibly using ARENA software Scope may necessitate Senior Design Project (primarily ISE) or multiple ISE co-ops Recommended in conversation with Professor John Kaemmerlen (ISE) 5/30/10 Rev 02

Questions or comments? Rev 02