Wegmans: Flip-Label Project

Team Members:

Brandon Sbordone (ME), George Kilger (EE), Ben Bouffard (EE), Ian Baker (ME),

Charlie Nicolosi (ME), Helen Jervey (ISE)

Customer Needs Hierarchy• Need 1: Product & Process are safe.

• Need 1.1: Product integrity is maintained. • Need 1.2: Equipment satisfies USDA Regulations as well as the AMI

Checklist. • Need 1.3: OSHA Safety requirements are met.

• Need 1.3A: Remove ergonomic issues and concerns. • Need 2: Reallocate Direct Labor.

• Need 2.1: Reallocate direct flipping labor. • Need 2.2: Reallocate direct alignment labor. • Need 2.3: Reallocate direct labeling labor. • Need 2.4: Camera labeling system is low priority.

• Need 3: Improve Processing Time. • Need 3.1: Maintain or decrease takt time. • Need 3.2: All packages get scanned by the x-ray at desired belt speed. • Need 3.3: Control flow to scaling operation. (Control flow-rate variance)

• Need 3.3A: Packages must flow in a format that works with the X-ray. • Need 4: Control orientation and flow-mechanics.

• Need 4.1: Packages are in the proper orientation. • Need 4.1A: Label is in proper orientation position relative to the

package. • Need 4.1B: All packages are centered in the x-ray beam.

• Need 4.1Ba: Packages are conveyed in single-file. • Need 4.2: Keep allocation of floor space constant.

Key Business Goals/Project Deliverables • Implement devices to automatically flip and align packages • Remove ergonomic risks• Devise quicker labeling process

Design Specifications and Test Results

Recommendations for Future Work• Implementation of automated labeling system would further reallocate labor resources.

• Implementation on the second production line doubles the benefits.• Automated package handling following labeling process.• Improvements to Multi-Vac system to meet maximum capacity of automated conveyor system.

Advisor: John Kaemmerlen (ISE)Customer: Wegmans

Championed by Chris Isaacson

Concept Selection

*Only top 3 options are shown

Problem StatementThe Flip-Label project goal is to reduce direct labor requirements for the flip/label meat package process sequence in the Wegmans Culinary Innovation Center. Currently an operator is needed to manually flip and align meat packages to enter the x-ray inspection machine. One or more operators are needed to label packages after they exit the inspection machine depending on product type and process speed.Objectives• Implement devices to flip and arrange meat packages in optimal

configuration on conveyor for inspection by x-ray scanner• Reduce direct labor needed to label packages at current takt

Acknowledgements

System Hierarchy

Layout offered minimal impact to room layout, while managing to maintain required product flow without undesirable equipment purchases.

Metric Need Met Description Imp. Units Marginal Value Ideal Value

5 N 1,2 FDA/USDA Specs 5 Pass/Fail Pass Pass

6 N 1,2,15 AMI Sanitary Design Checklist 5 Pass/Fail Pass Pass

7 N 1,3 OSHA Safety Specs 5 Pass/Fail Pass Pass

10 N 6,7 Direct Flip/Align Man Hours 5 hours <75% Current <50% Current

11 N 1 Keep Product Integrity 5 Pass/Fail Pass Pass 8 N 9,12 Flip 4 Pass/Fail Pass Pass 9 N 4,8 Belt Speed (X-Ray) 4 m/s or ft/s Current Current

10 N 5 Direct Label Man Hours 4 Hours <75% Current <50% Current

12 N 15 Ergonomic Risk 4 CIC Risk Assess units Current <24 1 N 4,13 Flow Rate 3 pc/min 7 >7 4 N 9,12 Label Orientation 3 Deg 85-95 902 N 9,10,12,13,14 Pc. Alignment 2 in from center TBD 03 N 9,12 Pc. Perpendicularity 2 Deg 85-95 90

13 N 11,14 Flow Rate Variance 1 % of Rate +/- 25-50% +/- 0-25%

Flip Align X-Ray Label

Selected Concepts

• Due to concerns about getting the other project sections implemented before moving forward with the fully automated labeling system, a label assist system was employed in the interim period. This system was designed to increase labeling speed and reduce strain on workers.

• The flipper mechanism is the first component encountered in the system, it is required in-order to put product in an orientation that improves labeling accessibility. It was critical that flip motion be controlled and that it repeatability dispenses product onto variable speed belt system for aligning.

• The aligning solution had to offer complete product support with minimal change-over time between products. Precision feedback systems offered exact control over product location on belt surface, and simple user interfaces allows employees to easily select product on the line, which will in-turn recalibrate entire system.

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