EDGE™ Systems Level Design Review P Automation/Improvement of Wegmans Cookie Line Packaging Project Team: Stephanie Rager (IE), Bruno Coelho (ME), Mark Voss (ME), Chukwuma Morah (IE), Brian Duffy (EE), Benjamin Powell (EE)

EDGE™ Project Overview Objective: Receive feedback from others about our design Become more aware of other potential risks Project Description: Wegmans bakes and packages all of their mini cookies at their bakeshop located here in Rochester on Brookes Avenue. Currently the packaging is done by six or seven people who stand around a conveyor and pull the cookies into the clam-shell packages. This leads to the problem of packing more cookies than needed into a package. The mini-cookie package calls for 397 grams worth of cookies but employees sometimes package up to 450 grams. This is a loss for Wegmans because customers are receiving more cookies than they are paying for. This project will look into building an automated prototype that will separate the cookies into the correct amount by weight, which the employees can then package.

EDGE™ Customer Needs Hierarchy Need 1: Separates Products by Weight Need 1.1 Must separate Mini-Cookies by weight (9) Need 1.2 Must separate Mini-Muffins by weight (5) Need 1.3 Must separate Brownie Bites by weight (5) Need 2: Waste Reduction Need 2.1 Must Reduce the amount of excess mini-cookies in package (9) Need 3: Separates Products by Count Need 3.1 Must separate Cookie Chunks by count (3) Need 3.2 Must separate other products by count that are packaged in that way on this line (3) Need 4: Long Term Solution Need 4.1 Must be adjustable for other products (5) Need 4.2 Must not substantially slow down the process (9) Need 5: Labor/Employee Use Need 5.1 Must be simplistic for employees to use (9) Need 5.2 Must not create a substantial amount of extra labor for employees (9) Need 5.3 Must be repeatable for employees (9) Need 6: Food Environment Restrictions Need 6.1 Must be stainless steel (if final product is permanent) (9) Need 6.2 Must not be painted (9) Need 6.3 Must be water tight (9) Need 6.4 Must meet the NEMA4 level (will take a light water hose spray) (9) Need 7: Budget/Cost Need 7.1 Must not be considered a capital investment (> $10,000) (9)

EDGE™ Target Specifications Metric No.Need Nos.MetricImportanceUnitsMarginal valueIdeal Value 1 Need 1.1, 1.2, 1.3, 2.1 Percentage of packages with excess cookies (currently at 95%) 9%60%0% 2 Need 6.1, 6.2, 6.3, 6.4 Follows Wegmans' sanitation standard 3Y/NNY 3 Need 4.1, 5.1, 5.2, 5.3 Requires training that takes X minutes 5minutes6015 4Need 4.1, 4.2, 5.2Changeover time5minutes205 5 Need 1.1, 1.2, 1.3, 3.1, 3.2 Accurately separates product for packaging 9Y/NYY 6Need 4.2Throughput5 average packages per hour Need 7.1Cost9$< $10,000< $5,000 Importance Scale: 9 = These metrics will be the main focus of this project. 5 = These metrics will be a secondary focus of the project if time allows. 3 = These metrics will not be focused on unless the main and secondary metrics have been addressed.

EDGE™ Economic Analysis Summary Eliminating packages with 6 or more extra cookies: Assuming average volume all year (10 hours per week) Improved Hourly Throughput = = 1597 packages per hour Cost per package savings = $0.08 per package $0.08 * 1500 packages = $120 saved per hour $120 * 10 hours = $1200 saved per week $1200 * 52 weeks = $62,400 saved per year Eliminating packages with 2 or more extra cookies: Assuming average volume all year (10 hours per week) Improved Hourly Throughput = = 1696 packages per hour Cost per package savings = $0.16 per package $0.16 * 1500 packages = $240 saved per hour $240 * 10 hours = $2400 saved per week $2400 * 52 weeks = $124,800 saved per year

EDGE™ Overall System Design Model

EDGE™ Sectional Top View Models

EDGE™ Board Design and Functionality Overview FPGA - Controls motors - Receives inputs from external signals - Sends signals to external signals - Runs Program Flash Memory - Stores program SDRAM - Stack Memory - Program Memory - I/O storage RS232 - I/O from weight sensor 1 RS232 - I/O from weight sensor 2 Motor 1 - motor connector to sifter bar Motor 2 - motor connector to conveyer belt Motor 3 - motor connector to chute device Motor 4 - motor connector to lever arm on weight sensor 1 Motor 5 - motor connector to lever arm on weight sensor 2 Power Connector Power protection circuitry STOP Internal Safety Switch along with leads to external switch

EDGE™ Timing Diagram

EDGE™ Failure Mode Analysis FailureSeverityProbabilityOverallContingency Plan Clog of cookies within the line chute section of assembly 343.5Sifter The incline gate causes a bottleneck and back-up the conveyor 333 Move to converyor closer, or make the incline gate longer The motor may not move fast enough from one weigh station to the other without dropping excess cookies into the weigh station 333 Stop door in chute, sensor The incline gate cannot actually come in contact with the conveyor that is already in place Ratchet system to lock incline gate into place, wheels Response time on the scale is not quick enough533 Better scales, more sensors, money Importance Scale: 1 through 5 1 = lowest 5 = highest

EDGE™ Risk Assessment RiskSeverityProbabilityOverallContingency Plan Team won't have enough time to create to entire prototype Create only a third of the working prototype Long lead times on ordered parts may push prototype production back 433.5Order parts as early as possible Weighing technology does not meet expectations 423 Extensively research alternative weighing devices, spend more money on improved weighing device Insufficient funds to produce full design534 Create only a third of the working prototype, extensively research the best and most cost effective materials for prototype Mechanical and Electrical systems don’t interface well with each other Be aware of the interface between the two, constant communication between electrical and mechanical engineers Cookies don’t get pulled by incline gate333Strong testing procedure Incline gate does not switch up132Strong testing procedure Cookies get stuck in funnel section354Use “shaking wheel” Weigh station doesn’t push out cookies quickly enough 333Strong testing procedure Chutes don’t switch quickly enough333Strong testing procedure Settling time is too long333Strong testing procedure/part research Chute doors don’t open/close at right time333Strong testing procedure Conveyor failure333Create emergency stop switch Importance Scale: 1 through 51 = lowest5 = highest