1. Sponsored by Wegmans P09711 - Automation/Improvement of Packaging on the Cookie Line Stephanie Rager Bruno Coelho

2. Automation/Improvement of Packaging on the Cookie Line LinePhase IPhase IIPhase IIIPhase IV Cookie Line Automation Automated Scaling of Cookies Automated Scaling of other Products Automated Packaging for Cookie Line Integration of Systems

3. Automation/Improvement of Packaging on the Cookie Line

5. Project Name Automation/Improvement of Packaging on the Cookie Line Project Number P09711 Roadmap R09710- Modern Food Processing and Bakery Technology for Lean Production Systems Start Term 2008-2 End Term 2008-3 Faculty Guide Professor Kaemmerlen (Industrial and Systems Engineering Department) Primary Customer Wegmans Scott Young Chris Isaacson

6. Automation/Improvement of Packaging on the Cookie Line Project Summary Wegmans bakes and packages all of their mini cookies at their bakeshop located here in Rochester on Brooks 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. Employees should be packing 398 grams into a package Employees are packing sometimes up to 450 grams of cookies 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.

7. Automation/Improvement of Packaging on the Cookie Line Mission Statement Create an automated prototype that will separate mini cookies by weight, while preventing cookies from moving on in the process until a specified weight is reached. It will create a clear separation between the sets of cookies that go into each package without substantially slowing down the packaging process.

8. Project Stakeholders Primary Customers: Wegmans Facility and Employees Scott Young, Manufacturing Engineering Manager Chris Isaacson, Industrial Engineer Other Stakeholders: John Kaemmerlen, Faculty Advisor Mark Smith, RIT Senior Design

9. Automation/Improvement of Packaging on the Cookie Line Key Business Goals/Project Deliverables Provide an effective design to minimize the packaging wastes Research materials and sensors to be used in automated prototype Produce an automated prototype Test/analyze effectiveness of prototype Present prototype to customer

10. Automation/Improvement of Packaging on the Cookie Line Assumptions and Constraints Budget Wegmans’ engineering resources Scheduling of benchmarking/testing time due to production goals Should not substantially slow down the packaging process

11. Automation/Improvement of Packaging on the Cookie Line Preliminary Customer Needs 1. Weights Product 1.1 Mini-Cookies 1.2 Mini-Muffins 1.3 Brownie Bites 2. Long Term Solution 2.1 Adjustable 3. Randomization 4. Waste Reduction 4.1 Reduces the amount of excess cookies in package

12. Automation/Improvement of Packaging on the Cookie Line Preliminary Risk Assessment Cost/Budget Consequences- could not produce prototype Substantially slows down process Consequences- not useful in line, no implementation Technology- needed technology is not available Consequences- unable to produce effective prototype Reduce Quality- design effects cookies Consequences- design and prototype cannot be implemented

13. Automation/Improvement of Packaging on the Cookie Line Staffing Requirements NameDisciplineRole John Kaemmerlen Faculty Guide Faculty Guide, will work closely with the team on an on-going basis to facilitate success of project. Stephanie RagerIE Will serve as Project Manager. Assist in identifying the current process for packaging. Perform analysis on current process to be used as a benchmark for testing final prototype. Bruno CoelhoME Will serve as Chief Engineer. Act as main point of contact from an engineering standpoint. Assist in creation and production of an effective prototype. TBDME Establish an effect engineering design for project. Research materials to be used in prototype. TBDEE Research sensors to use to collect the weight of the cookies. Program sensors to be used in prototype. TBDEE Research proper electronics to be used in mechanical system. Implement electronics in system/prototype.

14. Automation/Improvement of Packaging on the Cookie Line Preliminary Work Breakdown Structure PersonWeek 0-1 TasksWeek 1-2 TasksWeek 2-3 Tasks Stephanie Rager – Project Manager Meet with Bruno to discuss specific team assignments. Set up first meeting before Friday. Conduct the meeting, and provide each group member with their assignments to be completed by the next Fridays meeting. Organize a site visit to Wegmans for entire team. Conduct a brainstorming session with project team to generate initial design ideas. Review the project schedule with the project team. Compile research performed in various fields by the project team. Organize and conduct a team meeting to monitor individual progress. Address areas of conflict with individual team members as they apply to them. Bruno Coelho – Chief Engineer Meet with Stephanie to discuss specific team assignments. Assist in conducting the meeting and provide overview of project to team members. Conduct a brainstorming session with the project team to generate initial design ideas. Provide each group member with their assignments to be completed by the next Fridays meeting. Generate concept design of mechanical system. Organize and conduct meeting with team to discuss individual concept designs. Provide team members with their assignments to be completed by the next Fridays meeting. ME Familiarize themselves with the project by thoroughly examining the project readiness package located on the EDGE website. Research possible materials to be used in the mechanical system. Brainstorm some individual design ideas. Generate concept design of mechanical system. Continue to researching materials to be used in mechanical system. EE Familiarize themselves with the project by thoroughly examining the project readiness package located on the EDGE website. Research possible sensors to use in collecting weight. Brainstorm some individual design ideas. Generate concept design of researched sensors. Continue researching sensors to use in collecting weight. EE Familiarize themselves with the project by thoroughly examining the project readiness package located on the EDGE website. Research possible electronics to use in the mechanical system. Brainstorm some individual design ideas. Generate concept design of electronics to be used in mechanical system. Continue researching electronics to be used in mechanical system.