rit senior design project – p10711 wegman’s meat tumbler process improvement eric albanese –...
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RIT SENIOR DESIGN PROJECT – P10711WEGMAN’S MEAT TUMBLER PROCESS IMPROVEMENT
Eric Albanese – Project Manager, Industrial EngineerTheresa Ambrose – Mechanical EngineerOkechikere Ekeada – Industrial EngineerJeremy Gray – Industrial EngineerJesse Wykstra – Mechanical Engineer
PROJECT PURPOSE
The aim of this project is to improve the meat marinade tumbler transport in the Wegman’s Culinary Innovation Center. Our primary goals were to: Fix ergonomic issues Address safety concerns Reorganize layout Reduce waste
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Customer RequirementsCustomer
Importance
Total Risk Rating (Wegman’s Ergo
Analysis)Square Feet
of open space
Less back pain when loading multivac 9 X
Less shoulder pain when loading multivac 9 X
Easier to grab meat when table almost empty 9 X
Less back/shoulder pain when pushing tables 9 X
Less shoulder pain when scooping bulk foods 6 X
Easier to push vmag vats 9 X
Better/less stressful cleaning methods for carts 9 X
Easier to maneuver Column Dumper/ One worker to secure VEMAG Vat 9
X
Easier method to load carts into elevator 3 X
More room to push carts around 3 X
Better place to put used carts 3 X
Investigate necessity of long conveyor 3 X
TRANSLATING NEEDS TO METRICS
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PROJECT METRICS AND GOALSCustomer Requirements
What we're
measuring
Customer Importanc
e
Current Values
Marginal Values Ideal Values
Solved by Proposal #
Ergonomics Primary RiskRisk Rating
CurrentRisk Rating
TargetRisk Rating
Ideal
Less back pain when loading multivac Dumptable 9 Very High 72 24 1 3
Less shoulder, wrist, and elbow pain when loading multivac
Dumptable 9 Very High 72 24 1 3
Easier to grab meat when table almost empty
Dumptable 9 Very High 72 24 1 3
Less shoulder and wrist/elbow pain when scooping bulk foods
Dumptable 6 Very High 72 24 1 3
Less back/shoulder pain when pushing tables
Dumptable 9 High 36 24 1 3
Better/less stressful cleaning methods for carts
Dumptable 9 Very High 8 24 1 3
Easier to maneuver Column Dumper/ One worker to secure VEMAG Vat
Column Dumper
9 Very High 26 24 1 4
Easier to push vemag vats Vemag 9 High 3 24 1 5
Easier method to load carts into elevator
Vemag 3 Low 3 24 1 5
Simplification Space UsedSpace Used
TargetSpace Used
Ideal
More room to push carts aroundSpace taken by carts/vats
3 301 ft^2 150 0 1
Better place to put used cartsSpace taken by carts/vats
3 301 ft^2 150 0 1
Better utilization of conveyor spaceSpace taken by conveyor
3 546 ft^2 273 0 2
PROJECT 1 - KAIZENGoals• Reduce # of VEMAG vat usage on the floor.• Reduce dumptable inventory in front of
Multivac station.
Problems addressed• Excessive # of VEMAG vats• Too much full dumptable inventory
Used lean implementation tool, Kaizen to identify and eliminate waste.
Used process signals to establish a pull system.
KAIZEN RESULTS
Reduced amount of space taken up by vemag vats From 85 ft2 to 56 ft2
Reduced amount of space taken up by dump tables. From 190 ft2 to 82 ft2
Established a pull system by implementing process limits between stations, reducing inventory.
PROJECT 2 – MEAT CONVEYOR Goal of the project is reduce the space
taken up the meat flattening progress
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With the possibility of other tumbler process being moved into this room (estimated at least additional 32 sqft), better space utilization is a necessity
• Wegman’s had smaller conveyor in Brockport, NY facility that was transported to the CIC
• New conveyor is 18’ long, old one was 26’ long• Worked to optimize the space use of the new machine
• Reworked layout to minimize amount of ‘dead space’.• Completed ergonomic study to ensure safety
CONVEYOR – RESULTS
Process converted successfully to smaller sized conveyor
Space taken reduced Production capacity
determined to
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Customer Requirements What we're measuring
Previous Value Marginal Value
Ideal Values Actual Value
Simplification Space UsedSpace Used
TargetSpace Used
Ideal
Better utilization of conveyor spaceSpace taken by conveyor
546 ft^2 273 ft^2 0 ft^2 270 ft^2
PROJECT 3 - DUMP TABLE
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Project Goals:• Reduce the amount of
bending/twisting required to unload the dump table at the multivac station.
• Improve the overall maneuverability of
the dump tables.• Simplify the dump table
cleaning process. Results: A spring loaded UHMW plastic insert greatly reduced the
amount of bending/twisting that the employees have to perform while unloading the dump table at the multivac station.
The maneuverability of the dump table will be improved by adding a new caster design.
The cleaning process will be improved by adding a removable drain bucket.
SPRING-LOADED DUMP TABLE PROTOTYPE
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Item #
Description
Qty
1 Caster 42 Cart 1
3 Fixed Post 4
4 Slider Post 4
5 Spring 46 Grate 17 Drain Bucket 1
Item Description Price
1 .115” Stainless Compression
Spring
$299
2 .120” Stainless Compression
Spring
$299
3 0.75” OD Stainless Tubing
$107
4 1.25” OD Stainless Tubing
$372
5 0.25” OD Stainless Rod
$0.80
6 Stainless Sheet Metal
$29
7 Perforated Stainless Sheet
Metal
$60
8 1” OD Stainless Ball
$61
9 6” OD Stainless Swivel Casters
$480Total Cost: ~$1,708
DUMP TABLE RESULTS
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The spring-loaded grate mechanism was completed in the RIT machine shop.
The removable drain bucket will have to be completed by Wegmans.
The new casters will also have to be installed by Wegmans.
All of the new dump table features will have to be tested.
These new features will improve the ergonomics involved with unloading, transporting, and cleaning the dump table.
PROJECT 4 – COLUMN DUMPER
Goals Make column dumper require less force to
move Reduce the number of workers required to
load column dumper with VEMAG Vat and secure it
Problems addressed Ergonomic concerns workers have
(complaints of a stressed and strained body after a busy day)
Reduce waste involved with using two workers to properly secure VEMAG Vats
COLUMN DUMPER – SUGGESTED MODSSecondary Securing Mechanism: Upside – out of the
way Downside – install on
every vat Carabiner
Test the purchased casters Force Gauge Worker survey
Purchase suggested casters
Modify Column Dumper for 6” casters
PROJECT 5 – VEMAG VATS 3 Injuries:
Shoulder pain while working in the tumbling area
“A shooting pain” in hamstring from pushing a small empty vat out of the way
While pushing a full vat into the power lifter, shooting pain in shoulder
Loading into dumper: Very large push required
for vat to “click” securely in place
VEMAG HANDLE
VEMAG RESULTS
Vat handle was constructed and attached successfully Used round stainless steel tubing for easier
bending and welding 1/8” thick, 1” OD, same lengths
Ergonomic risk rating was reduced from 3 to 1 Still not a large risk, but the injuries related to
bending are going to practically disappear Initial feedback from team members and
machine shop staff is very positive Waiting on feedback from floor employees
RESULTS OF ALL PROJECTS
Customer RequirementsWhat we're
measuring
Current Values
Marginal Values
Actual Values
Met Goals
Ergonomics Primary RiskRisk Rating
CurrentRisk Rating
TargetRisk Rating
ActualYes/No
Less back pain when loading multivac Dumptable Very High 72 24 1Expected
Less shoulder, wrist, and elbow pain when loading multivac
Dumptable Very High 72 24 1Expected
Easier to grab meat when table almost empty
Dumptable Very High 72 24 1Expected
Less shoulder and wrist/elbow pain when scooping bulk foods
Dumptable Very High 72 24 1Expected
Less back/shoulder pain when pushing tables
Dumptable High 36 24 1Expected
Better/less stressful cleaning methods for carts
Dumptable Very High 8 24 1 Expected
Easier to maneuver Column Dumper/ One worker to secure VEMAG Vat
Column Dumper
Very High 26 24 N/A NO
Easier to push vemag vats Vemag High 3 24 1 Yes
Easier method to load carts into elevator
Vemag Low 3 24 1 Yes
Simplification Space UsedSpace Used
TargetSpace Used
Ideal
More room to push carts aroundSpace taken by carts/vats
301 ft^2 150 0 Yes
Better place to put used cartsSpace taken by carts/vats
301 ft^2 150 0 Yes
Better utilization of conveyor spaceSpace taken by conveyor
546 ft^2 273 270 Yes
PROJECT WRAP-UP
SUCCESSES: ISSUES:
Issues with parts tracking and ordering
Discovered some overlap with existing Wegmans projects and had to modify plans
Could have used more test time with prototypes
Email communication could be better
Miscommunications between involved parties
Process inventory controlled and reduced
Opportunities for other process additions to marinade room
Discovered and reinforced existing issues
Carried designs from concept to completion
Created working prototypes for mass production
Got experience working as consultants in a multidisciplinary team
MOVING FORWARD
Suggestions for Future MSD Projects: Collaborate with other MSD groups for parts
ordering/receiving Have large formal introduction meeting at
start where we meet everyone involved (management, parts ordering, operations, etc)
Less time should be spent on deliverables in MSD1 and more time spent on ordering, building, testing in MSD2
Keep standing meeting every week and cancel as needed
QUESTIONS?
THANK YOU!