P09711 Automation/Improvement of Packaging on Cookie Line
Final Test Plan
By: Stephanie Rager, Bruno Coelho, Chu Morah, Mark Voss, Ben Powell, Brian Duffy
Table of contents
1.MSD II: FINAL TEST plan
1.1.Overview
1.2.Sub-Systems/ Critical Components Being Tested
1.3.Approval
1.4.Test Strategy
1.5.Definitions & Terminology
P09711Automation/Improvement of Packaging on Cookie Line
Final Test Plan
1.MSD II: FinalTEST plan
1.1.Overview
1.1.1.Project Purpose
The purpose of this project is to look into building an automated prototype that will separate the cookies into the correct amount by weight, which the employees can then package.
1.1.2Document Purpose
The intent of this document is to specify the testing equipment, strategies, and procedures required to evaluate and verify the Cookie Line Prototype specifications and metrics which were derived from the customer needs.
1.2.Sub-Systems/ Critical Components Being Tested
1.2.1.Sifting Bar
1.2.1.1.Arrangement of cookies in lines
1.2.2.Tunnel
1.2.2.1.Flow of cookies into tunnel
1.2.3.Chute
1.2.3.1.Flow of cookies down chute
1.2.3.2.Movement of chute between weigh stations
1.2.4.Weigh Station
1.2.4.1.Accuracy of scale when cookies are flowing onto it
1.2.5.Push-rod
1.2.5.1.Reaction time when correct weight is reached
1.3.Approval
Approved by:
Team Members – Stephanie Rager, Bruno Coelho, Chu Morah, Brian Duffy, Ben Powell, Mark Voss
Guide & TA – Professor John Kaemmerlen, Phil Bryan
Sponsor – Wegmans, Scott Young, Chris Isaacson
1.4.Test Strategy
1.4.1.Prototype System Specifications to be Tested/ Marginal Performance Target / Ideal Performance Target
1.4.1.1.Prototype Throughput/ 375 packages per hr/ 425 packages per hr
1.4.1.2.Weight of Cookies in Package/ 420 grams/ 397 grams
1.4.1.3.Creates clear separation of product for packaging/ Y/ Y
1.4.2.Prototype Specifications and Sub-Components Testing Procedures
1.4.2.1.Sifting Bar- Arrangement of cookies in lines
Randomly arranged cookies will be placed on the conveyor. They will travel to the sifting bar. The lines formed by the sifting bar will be no more than 2.1 inches from outer edge to outer edge (of cookie). Adjust speed, teeth separation and throw of sifting bar as needed.
1.4.2.2.Tunnel- Flow of cookies into tunnel
If sifting bar has been tested and is performing as needed, cookies will be placed on conveyor in a random arrangement and will go through the sifting bar. Cookies will then continue to tunnel. The flow through the tunnel will be documented with photo and /or video. Adjust angle of funnel as needed in order to find optimal angle for minimal backlog.
1.4.2.3.Chute- Flow of cookies down chute
Once tunnel has been tested, cookies will be placed on conveyor before tunnel. A time to run test will be determined and the amount of cookies used will correspond to the length of time (4 cookies per second* 20 seconds for test). The amount cookies that flow down chute each second will be documented. Adjust angle of chute as needed.
1.4.2.4.Chute- Movement of chute between weigh stations
Cookies that have been previously weighed and are about two packages worth in weight will be sent down the conveyor. This should cause one package to be distributed into a weigh station and then the chute should move over to the next weigh station. The next amount of cookies would then be distributed in the next weigh station and the chute should then move over. This will be documented using photo and/or video and will be repeated multiple times. Adjust speed and angle of rotation of chute as needed.
1.4.2.5.Weigh Station- Accuracy of scale when cookies are flowing onto it
A group of cookies will be previously weighed on the scales. They will be sent down the conveyor. The scale readings after the cookies flow through the chute will be documented. If readings are inaccurate, the average of samples will be taken. It will be considered accurate if variance of reading on weigh scale to actual weight is less than 1 gram.
1.4.2.6.Push-rod- Reaction time when correct weight is reached
Two groups of cookies which have been weighed and are equal to two packages will be sent down the conveyor. Using a stop watch, the length of time it takes the push-rod to move the cookies out of the weigh station will be timed. Photo and/or video will be used to document if extra cookies are allowed into the weigh station due to the time it takes the push-rod to react. The reaction time will be deemed unacceptable if it is greater than 7.5 seconds (this includes the push-out and return of the cookies). Adjust speed of push-rod as needed.
1.4.2.7.Prototype Throughput
Cookies will be placed at the beginning of the conveyor. They will travel through the entire system. A team member will keep track of the # of groups of cookies that are pushed out of the weigh stations. Another team member will take these groups and place them back at the beginning of the conveyor to run through the system again. This will be done for one hour. Random groups will be weighed to ensure accuracy. The throughput will be deemed acceptable if 375 packages or more are filled.
1.4.2.8.Weight of Cookies in Package
40 Cookies will be placed at the beginning of the conveyor. They will travel through the entire system. A team member will weigh the groups that are pushed out of the weigh station. These weights will be documented. The package weight will be deemed unacceptable if the package has a weight of greater than 422 grams.
1.4.2.9.Creates clear separation of product for packaging
Cookies will be placed at the beginning of the conveyor. They will travel through the entire prototype system. Using a stop watch, the time between each group of cookies being pushed out of the weigh station will be documented. The arrangement of cookies will also be documented using photos. To verify the separation, team members will place a group of cookies on the beginning of conveyor and then using the documented time place another group. The separation between the two groups on the conveyor will be documented using video. If the separation time is greater than 7.5 seconds the time will be deemed unacceptable.
1.4.3.Test Equipment Available
1.4.3.1.Conveyor
1.4.3.2.Wegmans Mini-Chocolate Chip Cookies
1.4.3.3.Stop Watch
1.4.3.4.Digital Camera with ability to take video
1.4.3.5.Digital Scale
1.4.4.Phases of Testing
1.4.4.1.Component/ Device (wks 2-12)
- Incline Gate
- Sifting Bar
1.4.4.2.Integration (wks 11-15)
- Tunnel
- Chute
- Weigh Station
- Push-Rod
1.4.4.3.Reliability (wks 15-20)
Weight of Cookies in Package
1.4.4.4.Customer Acceptance (wks 20-21)
Throughput
Creates clear separation of cookies for packaging
1.5.Definitions & Terminology
1.5.1.Sifting Bar: The bar that moves back and forth to position the cookies into lines.
1.5.2.Tunnel: Keeps the cookies in their lines moving towards their set of weigh stations. There is one tunnel for every two weigh stations and four lines of cookies.
1.5.3.Chute: The system that moves between the two weigh stations.
1.5.4.Weigh Stations: The station where a scale has been placed in order to weigh the cookies for packaging.
1.5.5.Push-Rod: The device that is used to move the cookies off of the scale after being weighed.
1.5.6.Package Weight: A package of Wegmans mini chocolate chip cookies should weigh 397 grams.