© 2004 Kraft Senior Design Project© 2004 Kraft Senior Design Project

Improvements to Juice Work Improvements to Juice Work CellCell

Team Members:Team Members:

Jessica Vastola - ISEJessica Vastola - ISE

James Hildick - MEJames Hildick - ME

Molly Kearns - ISE Molly Kearns - ISE

Michael Leiston - MEMichael Leiston - ME

Laura Pleten - MELaura Pleten - ME

Michael Russell - MEMichael Russell - ME

Nicole Verley - MENicole Verley - ME

© 2004 Kraft Senior Design Project© 2004 Kraft Senior Design Project

AgendaAgenda BackgroundBackground Needs AssessmentNeeds Assessment Concept DevelopmentConcept Development Feasibility AssessmentFeasibility Assessment Design SpecificationsDesign Specifications Analysis & SynthesisAnalysis & Synthesis Conclusion & Next StepsConclusion & Next Steps QuestionsQuestions

© 2004 Kraft Senior Design Project© 2004 Kraft Senior Design Project

BackgroundBackground

Kraft Lunchables with juice pouchesKraft Lunchables with juice pouches Movie clipMovie clip

Scope - Juice SupplyScope - Juice Supply 10-packs10-packs Current ergonomic risk factor Current ergonomic risk factor Current toolCurrent tool

© 2004 Kraft Senior Design Project© 2004 Kraft Senior Design Project

Needs AssessmentNeeds Assessment

Project Mission StatementProject Mission Statement Product DescriptionProduct Description Scope LimitationsScope Limitations Key Business GoalsKey Business Goals Financial ParametersFinancial Parameters

© 2004 Kraft Senior Design Project© 2004 Kraft Senior Design Project

Critical Performance Critical Performance ParametersParameters

Order QualifiersOrder Qualifiers Reduce ergonomic risk Reduce ergonomic risk

factorfactor Maintain line speedMaintain line speed Reduce required number Reduce required number

of passes of passes Meet safety regulations Meet safety regulations

and industry standardsand industry standards Weigh less than 10 Weigh less than 10

poundspounds Measure less than Measure less than

16”x10”x12”16”x10”x12”

Order WinnersOrder Winners Open four 10-packs at Open four 10-packs at

onceonce Clean & sanitize easilyClean & sanitize easily Consist of off-the-shelf Consist of off-the-shelf

materials for easy materials for easy replacement partsreplacement parts

Maintain juice pouch Maintain juice pouch integrityintegrity

Require one operatorRequire one operator Assist operation via Assist operation via

pneumaticspneumatics

© 2004 Kraft Senior Design Project© 2004 Kraft Senior Design Project

Concept AlternativesConcept Alternatives ““THE WEDGE”THE WEDGE” Handheld ToolHandheld Tool Stationary ToolStationary Tool

0

1

2

3

4T1

T2

E1

S1

S2

S3R1

R2

R3

R4

R5

Wedge

Handheld

Stationary

Baseline

© 2004 Kraft Senior Design Project© 2004 Kraft Senior Design Project

Concept DevelopmentConcept Development

Baseline concept – Kraft toolBaseline concept – Kraft tool Desire to open box in one Desire to open box in one

passpass Toggle designToggle design Tested required force for Tested required force for

openingopening PneumaticsPneumatics Desire to open one bundle Desire to open one bundle

© 2004 Kraft Senior Design Project© 2004 Kraft Senior Design Project

Design ConceptDesign Concept

© 2004 Kraft Senior Design Project© 2004 Kraft Senior Design Project

Feasibility AssessmentFeasibility Assessment

Design FeasibilityDesign Feasibility Materials FeasibilityMaterials Feasibility Fabrication FeasibilityFabrication Feasibility Cost FeasibilityCost Feasibility Ergonomic FeasibilityErgonomic Feasibility

© 2004 Kraft Senior Design Project© 2004 Kraft Senior Design Project

Design SpecificationsDesign Specifications Generates 300 lbs of Generates 300 lbs of

forceforce Operates with 110 psi Operates with 110 psi

plant pressureplant pressure Trigger ActuatedTrigger Actuated Desired weight < 10 lbsDesired weight < 10 lbs CompactCompact Build with food grade Build with food grade

materialsmaterials

© 2004 Kraft Senior Design Project© 2004 Kraft Senior Design Project

Analysis & SynthesisAnalysis & Synthesis

Force Force measurements & measurements & calculationscalculations

Pneumatic cylinder Pneumatic cylinder calculationscalculations

Estimated Estimated ergonomic risk ergonomic risk factorfactor

FORCE:# Risk Factor RVF1 Two handed lift greater than 20lbs 2F2 Vertical travel distance of lift, greater than 60" 0F3 Horizontal lifting reach greater than 20" from the body 0F4 Two handed carry greater than 30 lbs 0F5 Horizontal carry distance of greater than 20 ft 0F6 Two handed horizontal push / pull greater 40 lbs 0F7 Two handed vertical push / pull greater than 25 lbs 1F8 Trunk rotation with a weight greater than 10 lbs 2F9 Wrist rotation while manipulating greater than 6 lbs 0F10 One hand horizontal palmer push greater than 15 lbs 0F11 Use of hand tool greater than 7 lbs 2

FORCE RF TOTAL= 7

POSTURE:# Risk Factor RV

P1 Trunk forward flexion greater than 45o 0

P2 Trunk extension greater than 20o 0

P3 Neck flexion or extension greater than 45o 0P4 Trunk or next side-bent plus twisted 0

P5 Shoulder abduction greater than 90o 0P6 Working with hands or arms behind the body 0P7 Full elbow extension with shoulder elevation 0

P8 Elbow flexion greater then 135o 0

P9 Wrist flexion or extension greater than 65o 0

P10 Wrist ulnar or radial deviation greater than 25o 0P11 Forced pronation or supination of hand & wrist 0

POSTURE RF TOTAL= 0

OTHER RISK FACTORS: (Note: Each "Y"=RV Value of 2)# Risk Factor YESO1 Unusually high tool or floor vibration NO2 Frequent ladder or stair climbing NO3 High exposure to direct pressure or mechanical stress NO4 Work with hands over shoulder level for greater than 50% of cycle NO5 Squat or kneel for greater than 50% of cycle NO6 Stand on one leg for greater than 50% of cycle NO7 Awkward / immobile body position for greater than 50% of cycle NO8 Greater than 6 thumb and or finger exertions with one hand N

OTHER RF TOTAL= 0ERF Total= 7

© 2004 Kraft Senior Design Project© 2004 Kraft Senior Design Project

Analysis & SynthesisAnalysis & SynthesisCylinder Mounting PlateCylinder Mounting Plate

© 2004 Kraft Senior Design Project© 2004 Kraft Senior Design Project

Analysis & SynthesisAnalysis & SynthesisMainframeMainframe

© 2004 Kraft Senior Design Project© 2004 Kraft Senior Design Project

Analysis & SynthesisAnalysis & SynthesisGuide Rod PlateGuide Rod Plate

© 2004 Kraft Senior Design Project© 2004 Kraft Senior Design Project

Analysis & SynthesisAnalysis & SynthesisRod PlateRod Plate

© 2004 Kraft Senior Design Project© 2004 Kraft Senior Design Project

Failure Mode & Effects Failure Mode & Effects AnalysisAnalysis

Actions Taken

Sev

Occ

Det

RPN

Juice pouch punctured

5 Tool inserted too far due to too much force

2 Guide plate 1 10 readjust guide plate, repeat air pressure/throttle testing

Operator Accurate guide plate

5 1 1 5

Open Boxes Tool uncomfortable

Ackward handle orientation

7 Insufficient Design 1 Prototype testing 1 7 Alter design of handles

RIT Senior Design Team

Design and testing

7 1 1 7

Unsatisfatory grips 4 Insufficient Material 1 Removable rubber grips2 8 Replace rubber grip

Operator Designed to be removable

4 1 1 4

8 1 1 88 Replace rods Operator Reapplication of Lubrication

Open Boxes Fatigue/stress on the rods

Tool inoperable 8 Bushing Failure 1 Lead Bushings, Graphite spray Lubrication

1

1 6 Reorient toggle Operator

1 12

Open Boxes Toggle rotating on end of rod

Boxes fail to open 3 Insufficient anti-rotation mechanism

2 generally durable

Operator 2 torsion springs added

4 3generally durable 1 Open toggle bolt manually

28

Function

Toggle opening Malfunction

Open Boxes Boxes fail to open 4 Toggle not spreading properly, spring strength

7

SEV

Potential Effect(s) of Failure

Potential Failure Mode

Detec

Current Design Controls

Occur

Potential Cause(s)/ Mechanism(s) of

Failure

Action ResultsResponsibility

& Target Completion

Date

Recommended Action(s)

RPN

© 2004 Kraft Senior Design Project© 2004 Kraft Senior Design Project

Conclusion & Next StepsConclusion & Next Steps One passOne pass Reduce Ergonomic RiskReduce Ergonomic Risk Maintain Line SpeedMaintain Line Speed Contingency PlansContingency Plans

Use same concept, open less than 4 boxesUse same concept, open less than 4 boxes Re-design current hand toolRe-design current hand tool

Address Recent Kraft RecommendationsAddress Recent Kraft Recommendations Build and Test Build and Test Conduct Feasibility Assessment on entire Conduct Feasibility Assessment on entire

workstationworkstation

© 2004 Kraft Senior Design Project© 2004 Kraft Senior Design Project

QuestionsQuestions