Meeting Purpose: Systems level design review of P09711- Automation/Improvement of Packaging on Cookie Line. The objectives of this are to receive feedback from others about our design and to become aware of other potential risks that we have not thought of.
Meeting Date: January 15, 2009
Meeting Location: Building 09 Room 4435
Meeting time: 12:00 – 2:00 PM
Timeline:
Meeting TimelineStart time / Topic of Review / Required Attendees
12:00 / Project Background / Prof Kaemmerlen, Dr. Hoople, Mr. Bryan
12:15 / System Design / Prof Kaemmerlen, Dr. Hoople, Mr. Bryan
1:00 / Electrical System & Timing Diagram / Prof Kaemmerlen, Dr. Hoople, Mr. Bryan
1:15 / Failure Mode Analysis & Risk Assessment / Prof Kaemmerlen, Dr. Hoople, Mr. Bryan
1:45 / Wrap-Up Discussion / Prof Kaemmerlen, Dr. Hoople, Mr. Bryan
Project Background
Mission Statement:
The mission of this project is to 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.
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.
Customer Needs Hierarchy with Importance Ranking
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(if final product is permanent)
Need 6.1 Must be stainless steel (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)
Importance Scale:
9 = These needs have the highest importance.
5 = These needs are somewhat important.
3 = These needs are not as important as the rest of the needs.
Target Specifications
Metric No. / Need Nos. / Metric / Importance / Units / Marginal value / Ideal Value1 / 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 / 3 / Y/N / N / Y
3 / Need 4.1, 5.1, 5.2, 5.3 / Requires training that takes X minutes / 5 / minutes / 60 / 15
4 / Need 4.1, 4.2, 5.2 / Changeover time / 5 / minutes / 20 / 5
5 / Need 1.1, 1.2, 1.3, 3.1, 3.2 / Accurately separates product for packaging / 9 / Y/N / Y / Y
6 / Need 4.2 / Throughput / 5 / average packages per hour / 1500 / 1700
7 / Need 7.1 / Cost / 9 / $ / < $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.
Economic & Data Analysis
Average Weekly Volume = 15,151 packages
Runs on average 10 hours per week
Average hourly volume approx 1500 packages per hour
Average piece weight = 12 grams
Approx cookies per package = 32 cookies
Statistics from data collection:
Using average piece weight and approx cookies per package
Approx # of Extra Cookies / Percentage of Packages2 / 19.28%
4 / 43.14%
6 / 23.86%
8 / 7.19%
10 / 0.65%
2 Extra Cookies
19.28% of 1500 = 289 packages with approx 2 extra cookies
578 extra cookies = 18 packages
4 Extra Cookies
43.14% of 1500 = 647 packages with approx 4 extra cookies
2588 extra cookies = 81 packages
6 Extra Cookies
23.86% of 1500 = 358 packages with approx 6 extra cookies
2148 extra cookies = 67 packages
8 Extra Cookies
7.19% of 1500 = 108 packages with approx 8 extra cookies
864 extra cookies = 27 packages
10 Extra Cookies
0.65% of 1500 = 10 packages with approx 10 extra cookies
100 extra cookies = 3 packages
Economic & Data Analysis (Cont…)
Eliminating packages with 6 or more extra cookies:
Assuming average volume all year (10 hours per week)
Improved Hourly Throughput = 1500 + 67 + 27 + 3 = 1597 packages per hour
Using a cost per package provided by Wegmans:
- The original throughput (1500 packages per hour) was multiplied by the cost per package giving us the amount Wegmans spends per hour to make Mini-Chocolate Chip Cookies
- This cost per hour was divided by the new throughput (1597 packages per hour) to get a new cost per package
- The two costs were subtracted to determine the savings
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 = 1500 + 18 + 81 + 67 + 27 + 3 = 1696 packages per hour
Using a cost per package provided by Wegmans:
- The original throughput (1500 packages per hour) was multiplied by the cost per package giving us the amount Wegmans spends per hour to make Mini-Chocolate Chip Cookies
- This cost per hour was divided by the new throughput (1696 packages per hour) to get a new cost per package
- The two costs were subtracted to determine the savings
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
Full System Design Model
Sectional System Design Models
Board Design and Functionality Overview
Timing Diagram
Failure Mode Analysis
Risk Assessment
KGCOE MSDPage 1 of 12Technical ReviewMaterials