Sponsored by Wegmans

P09711 - Automation/Improvement of Packaging on the Cookie Line

Stephanie RagerBruno Coelho

Automation/Improvement of Packaging on the Cookie Line

Line Phase IPhase

IIPhase

IIIPhase

IVCookie

Line Automati

on

Automated Scaling of Cookies

Automated Scaling of

other Products

Automated Packaging for Cookie

Line

Integration of Systems

Automation/Improvement of Packaging on the Cookie Line

Automation/Improvement of Packaging on the Cookie Line

Automation/Improvement of Packaging on the Cookie Line

Project Name Automation/Improvement of Packaging on the Cookie LineProject Number P09711RoadmapR09710- Modern Food Processing and Bakery Technology for Lean

Production SystemsStart Term 2008-2 End Term 2008-3Faculty Guide Professor Kaemmerlen (Industrial and Systems Engineering Department) Primary Customer WegmansScott YoungChris Isaacson

Automation/Improvement of Packaging on the Cookie Line

Project SummaryWegmans bakes and packages all of their mini cookies at

theirbakeshop located here in Rochester on Brooks Avenue.

Currently the packaging is done by six or seven people who standaround a conveyor and pull the cookies into the clam-shell packages.

Employees should be packing 398 grams into a packageEmployees are packing sometimes up to 450 grams of

cookiesThis 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.

Automation/Improvement of Packaging on the Cookie Line

Mission StatementCreate 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 Stakeholders

Primary Customers: Wegmans Facility and Employees Scott Young, Manufacturing Engineering Manager Chris Isaacson, Industrial Engineer

Other Stakeholders: John Kaemmerlen, Faculty Advisor Mark Smith, RIT Senior Design

Automation/Improvement of Packaging on the Cookie Line

Key Business Goals/Project Deliverables

Provide an effective design to minimize the packaging wastes

Research materials and sensors to be used in automated prototype

Produce an automated prototypeTest/analyze effectiveness of prototype Present prototype to customer

Automation/Improvement of Packaging on the Cookie Line

Assumptions and ConstraintsBudgetWegmans’ engineering resourcesScheduling of benchmarking/testing

time due to production goalsShould not substantially slow down the

packaging process

Automation/Improvement of Packaging on the Cookie Line

Preliminary Customer Needs1. Weights Product

1.1 Mini-Cookies1.2 Mini-Muffins1.3 Brownie Bites

2. Long Term Solution2.1 Adjustable

3. Randomization4. Waste Reduction

4.1 Reduces the amount of excess cookies in package

Automation/Improvement of Packaging on the Cookie Line

Preliminary Risk AssessmentCost/Budget

Consequences- could not produce prototypeSubstantially slows down process

Consequences- not useful in line, no implementation

Technology- needed technology is not availableConsequences- unable to produce effective

prototypeReduce Quality- design effects cookies

Consequences- design and prototype cannot be implemented

Automation/Improvement of Packaging on the Cookie Line Staffing Requirements

Name Discipline

Role

John Kaemmerlen

Faculty Guide

Faculty Guide, will work closely with the team on an on-going basis to facilitate success of project.

Stephanie Rager

IE Will serve as Project Manager. Assist in identifying the current process for packaging. Perform analysis on current process to be used as a benchmark for testing final prototype.

Bruno Coelho

ME Will serve as Chief Engineer. Act as main point of contact from an engineering standpoint. Assist in creation and production of an effective prototype.

TBD ME Establish an effect engineering design for project. Research materials to be used in prototype.

TBD EE Research sensors to use to collect the weight of the cookies. Program sensors to be used in prototype.

TBD EE Research proper electronics to be used in mechanical system. Implement electronics in system/prototype.

Automation/Improvement of Packaging on the Cookie Line Preliminary Work Breakdown Structure

Person Week 0-1 Tasks

Week 1-2 Tasks

Week 2-3 Tasks

Stephanie Rager – Project Manager

Meet with Bruno to discuss specific team assignments. Set up first meeting before Friday. Conduct the meeting, and provide each group member with their assignments to be completed by the next Fridays meeting.

Organize a site visit to Wegmans for entire team. Conduct a brainstorming session with project team to generate initial design ideas. Review the project schedule with the project team.

Compile research performed in various fields by the project team. Organize and conduct a team meeting to monitor individual progress. Address areas of conflict with individual team members as they apply to them.

Bruno Coelho – Chief Engineer

Meet with Stephanie to discuss specific team assignments. Assist in conducting the meeting and provide overview of project to team members.

Conduct a brainstorming session with the project team to generate initial design ideas. Provide each group member with their assignments to be completed by the next Fridays meeting.

Generate concept design of mechanical system. Organize and conduct meeting with team to discuss individual concept designs. Provide team members with their assignments to be completed by the next Fridays meeting.

ME Familiarize themselves with the project by thoroughly examining the project readiness package located on the EDGE website.

Research possible materials to be used in the mechanical system. Brainstorm some individual design ideas.

Generate concept design of mechanical system. Continue to researching materials to be used in mechanical system.

EE Familiarize themselves with the project by thoroughly examining the project readiness package located on the EDGE website.

Research possible sensors to use in collecting weight. Brainstorm some individual design ideas.

Generate concept design of researched sensors. Continue researching sensors to use in collecting weight.

EE Familiarize themselves with the project by thoroughly examining the project readiness package located on the EDGE website.

Research possible electronics to use in the mechanical system. Brainstorm some individual design ideas.

Generate concept design of electronics to be used in mechanical system. Continue researching electronics to be used in mechanical system.