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KGCOE MSD Technical Review Agenda

Meeting Purpose: Detailed Design Review for Wegmans Flip-Label Team

Materials to be Reviewed:Detailed Design Review Presentation R00Detailed Design Review Handout R00

Meeting Date: 2/12/2010

Meeting Location: Wegmans Culinary Innovation Center Chili, NY

Meeting time: 3:00 – 4:30 pm

Timeline:

Meeting Timeline

Start Time

Topic of Review Required Attendees

3:00 Introduction/Goals of Presentation Design Team, Chris, John3:05 System Design Design Team, Chris, John3:10 Design Updates Design Team, Chris, John3:20 Flipping Design Team, Chris, John3:35 Aligning Design Team, Chris, John3:50 Labeling Design Team, Chris, John4:05 Cal-Pak Design Team, Chris, John4:20 Next Steps Design Team, Chris, John4:30 Conclude presentation Design Team, Chris, John

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Flip Label P10715 Detailed Design Review Handout R01Customer Needs Hierarchy

Need 1: Product & Process are Safeo Need 1.1: Product integrity is maintainedo Need 1.2: Equipment satisfies USDA Regulations as well as the AMI Checklist

o Need 1.3: OSHA Safety requirements are met Need 1.3A: Remove ergonomic issues and concerns

Need 2: Reallocate Direct Laboro Need 2.1: Reallocate direct flipping labor

o Need 2.2: Reallocate direct alignment laboro Need 2.3: Reallocate direct labeling labor

o Need 2.4: Camera labeling system is low priority Need 3: Improve Processing Time

o Need 3.1: Maintain or decrease takt time

o Need 3.2: All packages get scanned by the x-ray at desired belt speedo 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

o 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-fileo Need 4.2: Keep allocation of floor space constant

Ranked Customer Needs

Need The Product Needs to Imp.

N 1.1 Product integrity is maintained Meet specifications 5

N 1.2 Equipment satisfies USDA Regulations as well as the AMI checklist

Meet specifications 5

N 1.3 OSHA Safety requirements are met Meet specifications 4

N 2.1 Reallocate direct flipping labor Decrease man-hours 4

N 2.2 Reallocate direct alignment labor Decrease man-hours 4

N 2.3 Reallocate direct labeling labor Decrease man-hours 4

N 2.4 Camera labeling system is low priority Control project scope 4

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Flip Label P10715 Detailed Design Review Handout R01N 3.1 Maintain or decrease takt time Decrease processing

time 4

N 3.2 All packages get scanned by the x-ray at desired belt speed Scan all packages 3

N 4.2 Keep allocation of floor space constant Fit within specified area 3

N 3.3 Control flow to scaling operation(Control flow-rate variance)

Minimize variance 3

N 4.1A Label is in proper orientation and position relative to the package

Be aligned 3

N 4.1B All packages are centered in the x-ray beam Scan entire package 3

N 3.3A Packages must flow in a format that works with the X-ray Meet specification 2

N 4.1 Packages are in the proper orientation Be aligned 2

N 4.1Ba

Packages are conveyed in single-file Meet specification 2

N 1.3A Remove ergonomic issues and concerns Minimize risks 1

Importance Scale: 5 = Most Important, 1 = Preference Only

Engineering Metrics

MetricNeed Met Description Imp.UnitsMarginal

ValueIdeal Value

5 N 1, 2 USDA specs 5 Pass/Fail Pass Pass6 N 1, 2, 15 AMI Sanitary Design Checklist 5 Pass/Fail Pass Pass7 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%

Current11 N 1 Maintain product integrity 5 Pass/Fail Pass Pass8 N 9, 12 Flip product 4 Pass/Fail Pass Pass9 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 4CIC Risk Assess units

Current <24

1 N 4, 13 Flow rate 3 pc/min 7 >74 N 9, 12 Label orientation 3 Deg 85-95 90

3

Flip Label P10715 Detailed Design Review Handout R01

2N 9, 10, 12, 13, 14

Pc. alignment 2 in from center TBD 0

3 N 9, 12 Pc. perpendicularity 2 Deg 85-95 9013 N 11, 14 Flow rate variance 1 % of Rate +/- 25-50% +/- 0-25%

Importance Scale: 5 = Most Important, 1 = Preference Only

Projected System Cost

Subsystem Component Component Cost Subsystem Cost

Flipping

Parts & labor $2,600

Mounting TBD $2,600+

Aligning

Parts $2,100

Labor TBD

Conveyor TBD $2,100+

Camera

System TBD 2-18 TBD

Labeling

Cal-Pak TBD 2-18

Label assist $660 + enclosure

TBD

4

Flip Label P10715 Detailed Design Review Handout R01Revised System Footprint

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Flip Label P10715 Detailed Design Review Handout R01System Isometric View

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Flip Label P10715 Detailed Design Review Handout R01Flipper Assembly

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Flip Label P10715 Detailed Design Review Handout R01Flipper Drawing

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Flip Label P10715 Detailed Design Review Handout R01Welded Flipper Assembly

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Flip Label P10715 Detailed Design Review Handout R01Displacement Under Loading

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Flipping Bill of MaterialsPN Vendor Description Qty Cost TotalSSM-042.75-DW Bimba SS Bimba 3/4" Cylinder 2 $106.65 $213.30D-54565-SS Bimba SS Rod Clevis and Nut 2 $24.95 $49.90D-55203-SS Bimba SS Cylinder Pivot Bracket 2 $19.40 $38.80

4331K33 McMaster

Space-Saver Stacked Air Filter/Regulator Stainless Steel, 1/4" Pipe, 12 Max SCFM @ 100 PSI 1 $277.02 $277.02

9785K56 McMaster.104" 304SS 24x24 1 $163.21 $163.219785K36 McMaster.104" 304SS 12x24 1 $86.00 $86.008992K166 McMaster.125" 304SS 12x4 1 $14.12 $14.126620K62 McMaster.25" 304SS 6x6 1 $21.65 $21.658457K556 McMaster3/8" x 6' 304SS Tube 1 $32.89 $32.8998697A530 McMaster10-32 SS Weld Nut 10 Pack 1 $6.73 $6.7394912A330 McMaster10-32 SS SHCS, 5 Pack 1 $4.53 $4.53

6196K243 McMaster

Body-Ported Solenoid Air Control Valve Dbl Solenoid, 4-Way, 2-Pos, 1 Cv, 1/4" NPT, 24 VDC 1 $117.42 $117.42

1901K21 McMaster

Chemical-Resistant PVDF Tube Fitting Adapter for 1/4" Tube OD X 1/8" NPTF Male Pipe 4 $2.62 $10.48

5203K18 Polybutylene Manifold Swivel Tube Fitting 2 Outlets, for 1/4" Tube OD, 1/4" NPT Thread 2 $12.26 $24.52

9066K31 McMaster

Corrosion Resistant Air Flow Control Valve 1/4" Tube to 1/4" Tube Flow Control Direction 2 $20.60 $41.20

5390K31 McMaster3-A Sanitary White PVDF Tubing 1/8" ID, 1/4" OD, 1/16" Wall Thk, Semi-Clear 20 $2.10 $42.00

5111K548 McMasterPolybutylene & Brass Push-to-Connect Fitting Wye for 1/4" Tube OD, Gray 4 $4.91 $19.64

Labor Process Part/Description Time Rate All labor is estimate only

Cut/Form Flipper Tray 5 $80.00 $400.00Welding Flipper Tray 2 $80.00 $160.00

Cut/Form Flipper Mount 3 $80.00 $240.00 Welding Flipper Mount 2 $80.00 $160.00 Machine Mounts 3 $80.00 $240.00 Build Pneumatics/Controls 4 $40.00 $160.00

TOTAL$2,523.41

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Flipper Controls Block Diagram

12

Negative solenoidactivates for short time

Positive solenoid activates for short

time

Laser beam

reconnects

Laser beam broken


Aligning Proposed Solution

Flipper BOMPreliminary Bill of Materials to order from McMaster-Carr Rev-01

Item Part Number Qty

Unit Price Total

FDA-Compliant Rulon-Lined Guide Block, 1" Width

9728K3 4 $29.36 $117.44

13" Long Rail for 1" Width FDA-Compliant Rulon-Lined Guide Block

9728K62 4 $27.30 $109.20

Space-Saver Stacked Air Filter/Regulator Stainless Steel, 1/4" Pipe, 12 Max SCFM @ 100 PSI

4331K33 1 $277.02 $277.02

Body-Ported Solenoid Air Control Valve Dbl Solenoid, 4-Way, 2-Pos, 1 Cv, 1/4" NPT, 24 VDC

6196K243

1 $117.42 $117.42

Chemical-Resistant PVDF Tube Fitting Adapter for 1/4" Tube OD X 1/8" NPTF Male Pipe

1901K21 4 $2.62 $10.48

Polybutylene Manifold Swivel Tube 5203K18 2 $12.26 $24.52

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Fitting 2 Outlets, for 1/4" Tube OD, 1/4" NPT ThreadCorrosion Resistant Air Flow Control Valve 1/4" Tube to 1/4" Tube Flow Control Direction

9066K31 2 $20.60 $41.20

3-A Sanitary White PVDF Tubing 1/8" ID, 1/4" OD, 1/16" Wall Thk, Semi-Clear

5390K31 20 $2.10 $42.00

General-Purpose Track Roller with Stud Stainless Steel, 89 lb Dynamic Load Capacity

60135K51

4 $36.65 $146.60

1' Rail for 89 lb Dynamic Load Capacity, SS General-Purpose Track Roller wth Stud

60135K521

1 $34.16 $34.16

7' 1.25"x1.25" 304 SS L-Channel, 3/16" Thick

8993K45 5 $67.49 $337.45

Multipurpose Stainless Steel (Type 304) #2B Mill Finish, .060" Thick, 24" X 36"

8983K33 3 $54.01 $162.03

18mm Dia Body Light Beam Sensing Switch NPN, DC Input, Object Reflecting with Male Plug

65845K22

2 $94.73 $189.46

Washdown Stainless Steel Air Cylinder 3/4" Bore, 6" Stroke Length

6239K115

2 $123.56 $247.12

Miscelaneous Stainless Steel Hardware (Panels, Bolts, Wasters…etc)

N/A 1 $200.00 $200.00

Materials Total Estimated Cost$2,056.

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Flipper Hour Estimates

Estimates for time requirements of human resourcesItem Qty Hours Total

Design 1 30.00 30.00Programming of Actuation System 1 10.00 10.00Diagnostics and Trouble Shooting 1 10.00 10.00Miscelaneous Welded Connections 1 6.00 6.00Conveyor System Modification 1 5.00 5.00Cover Box Assembly with Pivot Support Bridge

2 2.00 4.00

Pivoting Arm Assembly 2 2.00 4.00Miscelaneous Bolted Connections 1 2.00 2.00Mounting of Actuation System 1 2.00 2.00Actuator Support Brace 2 1.50 3.00

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Actuator Mounting Bracket 2 1.50 3.00Pusher Plate Assembly 2 1.00 2.00Guide Rail Bracket 4 0.75 3.00Guide Rail Mounting 2 0.50 1.00 Total Estimated Time 85.00

System Integration and Occupancy

e

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Pusher Side Profile

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AppendixStress Analysis

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